Ford - F 150 2wd - Workshop Manual - 2008 - 2008

Factory Workshop Manual Make Ford Model F 150 2wd Engine and year V8-4.6L (2008) 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 F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8 Accessory Delay Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Vehicle Security Module (VSM) - Regular Cab Alarm Module: Service and Repair Vehicle Security Module (VSM) - Regular Cab VEHICLE SECURITY MODULE (VSM) - REGULAR CAB Removal CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage to the module may result. NOTE: - Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new vehicle security module (VSM) after installation. to carry out programmable module installation (PMI). - For the VSM to accept the PMI procedure, the following conditions must be met: a. the headlamp switch must be in the OFF position (must not be in the AUTOLAMP position, if equipped) b. the key must be in the ON position c. the driver door must be open d. the doors must be unlocked electronically by pressing the door lock control switch to the UNLOCK position momentarily Failure to follow this procedure will result in the PMI procedure to fail. - The tire pressure monitoring system (TPMS) functionality is integral to the VSM. - A new VSM is delivered in a "manufacturing mode" with 6 pre-set DTCs. These DTCs require that a successful configuration of the VSM occurs, then a successful TPMS sensor training occurs, then a successful self-test occurs, including the clearing of all DTCs. This is required in order to clear the 6 manufacturing mode DTCs. They are as follows: B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Vehicle Security Module (VSM) - Regular Cab > Page 14 - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is only necessary if the VSM is being replaced. Upload the module configuration information from the VSM into the scan tool. 2. Turn the key to the OFF position. 3. Remove the LH B-pillar trim panel. 4. Disconnect the 2 VSM electrical connectors. 5. Remove the 2 screws and the VSM. Installation 1. NOTE: If it is necessary to install new VSM mounting screw J-clips, they are available using part number W520822. Position the VSM and install the 2 screws. Tighten to 7 Nm (62 lb-in). 2. Connect the 2 VSM electrical connectors. 3. NOTE: If the VSM is not being replaced, this is the last step that is necessary. Install the LH B-pillar trim panel. 4. NOTE: When successful, this step provides the calibration necessary for the VSM operation and clears DTC B2477. The clearing of the DTC indicates the calibration data has been successfully downloaded to the VSM. Download the VSM configuration information from the scan tool to the VSM. 5. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the VSM has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 6. NOTE: - DTC C2780 will not clear if any other DTCs are present in the VSM. - This step is required to clear DTC C2780, allow the VSM to exit the manufacturing mode, and to make sure there are no other concerns with the newly programmed VSM. Carry out the VSM on-demand self-test by clearing the DTCs and then retrieving the DTCs to confirm all DTCs have been cleared. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Vehicle Security Module (VSM) - Regular Cab > Page 15 Alarm Module: Service and Repair Vehicle Security Module (VSM) - SuperCab and SuperCrew VEHICLE SECURITY MODULE (VSM) - SUPERCAB AND SUPERCREW Removal CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage to the module may result. NOTE: - Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new vehicle security module (VSM) after installation. to carry out programmable module installation (PMI). - For the VSM to accept the PMI procedure, the following conditions must be met: a. the headlamp switch must be in the OFF position (must not be in the AUTOLAMP position, if equipped) b. the key must be in the ON position c. the driver door must be open d. the doors must be unlocked electronically by pressing the door lock control switch to the UNLOCK position momentarily Failure to follow this procedure will result in the PMI procedure to fail. - The tire pressure monitoring system (TPMS) functionality is integral to the VSM. - A new VSM is delivered in a "manufacturing mode" with 6 pre-set DTCs. These DTCs require that a successful configuration of the VSM occurs, then a successful TPMS sensor training occurs, then a successful self-test occurs, including the clearing of all DTCs. This is required in order to clear the 6 manufacturing mode DTCs. They are as follows: B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Vehicle Security Module (VSM) - Regular Cab > Page 16 - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is only necessary if the VSM is being replaced. Upload the module configuration information from the VSM into the scan tool. 2. Turn the key to the OFF position. 3. Remove the rear seat backrest. 4. If equipped, remove the rear interior trim panel. 5. Disconnect the 2 VSM electrical connectors. 6. Remove the 2 screws and the VSM. Installation 1. Position the VSM and install the 2 screws. - Tighten to 7 Nm (62 lb-in). 2. Connect the 2 VSM electrical connectors. 3. If equipped, install the rear interior trim panel. 4. NOTE: If the VSM is not being replaced, this is the last step that is necessary. Install the rear seat backrest. 5. NOTE: When successful, this step provides the calibration necessary for the VSM operation and clears DTC B2477. The clearing of the DTC indicates the calibration data has been successfully downloaded to the VSM. Download the VSM configuration information from the scan tool to the VSM. 6. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the VSM has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 7. NOTE: - DTC C2780 will not clear if any other DTCs are present in the VSM. - This step is required to clear DTC C2780, allow the VSM to exit the manufacturing mode, and to make sure there are no other concerns with the newly programmed VSM. Carry out the VSM on-demand self-test by clearing the DTCs and then retrieving the DTCs to confirm all DTCs have been cleared. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: Customer Interest SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: All Technical Service Bulletins SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 30 Communications Control Module: Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 31 View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 32 Communications Control Module: Diagrams C290A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 33 C290B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 34 C290C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 35 Communications Control Module: Service and Repair AUDIO CONTROL MODULE (ACM) Removal and Installation NOTE: - If installing a new navigation audio control module (ACM), remove the navigation DVD if possible, before sending the ACM to an authorized audio system repair facility. - It is not necessary to remove the ACM to retrieve the part number. 1. Remove the instrument panel center finish panel. - Disconnect the electrical connectors. 2. Remove the 4 screws and the ACM. - Disconnect the electrical connectors and the antenna cable. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 39 View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 40 Keyless Entry Module: Diagrams C3008A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 41 C3008B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 45 C2023 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 46 Parking Assist Control Module: Service and Repair PARKING AID MODULE Removal and Installation 1. If replacing the parking aid speaker only, proceed as follows: - Disconnect the parking aid speaker electrical connector. - Disengage the parking aid speaker retaining clips. - Remove the parking aid speaker. 2. If replacing the parking aid module (PAM), proceed as follows: - Disconnect the electrical connectors. - Remove the PAM nuts. - Remove the PAM. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 47 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 52 View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 53 Keyless Entry Module: Diagrams C3008A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 54 C3008B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 58 Memory Positioning Module: Diagrams C341A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 59 C341B C314C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 60 C341D Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 61 Memory Positioning Module: Service and Repair DRIVER SEAT MODULE (DSM) Removal and Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new driver seat module (DSM) after installation. 1. Remove the driver seat. 2. Remove the 2 screws. - To install, tighten to 7 Nm (62 lb-in). 3. Disconnect the 4 electrical connectors and remove the DSM. 4. NOTE: Once the module is installed it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Locations Power Door Lock Control Module: Diagrams Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Locations > Page 66 View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Locations > Page 67 Power Door Lock Control Module: Diagrams Vehicle Security Module (VSM) C3008A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Locations > Page 68 C3008B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Locations View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Locations > Page 72 C3276 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Heated Seat Module, Driver Side Front View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Heated Seat Module, Driver Side Front > Page 77 View 151-29 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Heated Seat Module, Passenger Side Front C329 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Heated Seat Module, Passenger Side Front > Page 80 C359 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 81 Seat Heater Control Module: Service and Repair HEATED SEAT MODULE Exploded View Front Seat Backrest - With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 82 Front Seat Backrest - Without Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 83 Front Seat Cushion - Driver (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 84 Front Seat Cushion - Driver (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 85 Front Seat Cushion - Passenger (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 86 Front Seat Cushion - Passenger (Part 2) Removal and Installation WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the seat. 2. Disconnect the heated seat module electrical connector. 3. Detach and remove the heated seat module from the seat cushion frame 4. To install, reverse the removal procedure. 5. Install the seat. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations View 151-35 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 90 C921 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 96 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 97 Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 98 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 99 Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Reversing Lamp Non-Serviceable Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations View 151-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 104 C135 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 105 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Anti-Lock Brake System (ABS) Module Removal and Installation CAUTION: Electronic modules are sensitive to electrical charges. The anti-lock brake system (ABS) module can be damaged if exposed to these charges. CAUTION: When installing a new anti-lock brake system (ABS) module or hydraulic control unit (HCU), do not use the pump motor harness as a carrying handle. Failure to follow these instructions may result in damage to the HCU assembly. All vehicles 1. Disconnect the battery ground cable. For additional information, refer to Battery. Vehicles equipped with 5.4L engine 2. Remove the air cleaner intake pipe. For additional information, refer to Fuel Delivery and Air Induction. All vehicles 3. Disconnect the ABS module electrical connector. 4. Remove the 4 screws and the ABS module. ^ To install, tighten to 3 Nm (27 lb-in). 5. NOTE: The ABS module is not repairable. If an internal problem exists, a new part must be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 106 To install, reverse the removal procedure. When installing a new ABS module, it must be configured (using vehicle as-built data) and calibrated. Follow the scan tool directions for calibration procedures. For additional information on configuration, refer to Information Bus (Module Configuration). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 114 Blower Motor Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 115 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 119 Compressor Clutch Relay: Description and Operation AIR CONDITIONING (A/C) CLUTCH RELAY (A/CCR) NOTE: The PCM PIDs WAC and wide open throttle air conditioning cutoff fault (WACF) are used to monitor the A/CCR output. The A/CCR is wired normally open. There is no direct electrical connection between the A/C switch or electronic automatic temperature control (EATC) module and the A/C clutch. The PCM receives a signal indicating that A/C is requested. For some applications, this message is sent through the communications network. When A/C is requested, the PCM checks other A/C related inputs that are available, such as A/C pressure switch and A/C cycling switch. If these inputs indicate A/C operation is OK, and the engine conditions are OK (coolant temperature, engine RPM, throttle position), the PCM grounds the A/CCR output, closing the relay contacts and sending voltage to the A/CCR. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > 4x4 Relay Box Compressor Clutch Relay: Testing and Inspection 4x4 Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > 4x4 Relay Box > Page 122 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > 4x4 Relay Box > Page 123 Compressor Clutch Relay: Testing and Inspection 4x2 Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > 4x4 Relay Box > Page 124 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > HVAC Module, EATC View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > HVAC Module, EATC > Page 129 View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC Module, EATC Control Module HVAC: Diagrams HVAC Module, EATC C228A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC Module, EATC > Page 132 C228B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC Module, EATC > Page 133 Control Module HVAC: Diagrams HVAC Module, EMTC C294A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC Module, EATC > Page 134 C294B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamps (DRL) Enable Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamps (DRL) Enable Relay > Page 143 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Relay Daytime Running Lamp Relay: Testing and Inspection Daytime Running Lamps (DRL) Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Relay > Page 146 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Relay > Page 147 Daytime Running Lamp Relay: Testing and Inspection Daytime Running Lamps (DRL) Enable Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Relay > Page 148 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations Exterior Lighting Module: Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 152 View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 153 Exterior Lighting Module: Diagrams C3008A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 154 C3008B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 158 Fog/Driving Lamp Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 162 C2047 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 163 Hazard Flasher Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 167 High Beam Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 168 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 176 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 177 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 180 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 181 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 182 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 183 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Reversing Lamp Non-Serviceable Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 187 C2047 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 188 Turn Signal Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 196 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 204 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 205 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 206 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 207 Relay Box: Locations Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 208 Relay Box: Diagrams C270A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 209 C270B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 210 C270C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 211 C270D Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 212 C270E Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 213 C270F C270G Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 214 C270H Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 215 C270J Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 216 C270K Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 217 C270M Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 218 C270N C270P Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 221 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 222 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 223 Relay Box: Application and ID Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 224 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The torque based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable camshaft timing (VCT) (deliver same torque during transitions). Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with smoother traction control. Other benefits of ETC are: eliminate cruise control actuators - eliminate idle air control (IAC) valve - better airflow range - packaging (no cable) - more responsive powertrain at altitude and improved shift quality The ETC system illuminates a powertrain malfunction indicator (wrench) on the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The ETB has the following characteristics: - The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). - There are 2 designs: parallel and in-line. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-line design has a separate motor housing. - An internal spring is used in both designs to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. - The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (approximately 0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. - The required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. - There is 1 reference voltage and 1 signal return circuit between the PCM and the ETB. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. There are also 2 TP signal circuits for redundancy. The redundant TP signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The TP2 signal reaches a limit of approximately 4.5 volts at approximately 45 degrees of throttle angle. Accelerator Pedal Position (APP) Sensor Depending on the application either a 2-track or 3-track APP sensor is used. Electronic Throttle Control (ETC) System Strategy ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 230 ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 231 ETC System With A 2-Track APP Sensor Failure Mode And Effects Management Electronic Throttle Monitor Operation Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 232 The torque based ETC strategy was developed to improve fuel economy and to accommodate variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain control processor unit (CPU) and a separate monitoring processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, appropriate corrective action is taken. APP and TP Sensor Inputs Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check Electronic Throttle Actuator Control (TAC) Output Electronic TAC Operation Check Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations Engine Control Module: Locations View 151-2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 236 View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 237 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 238 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 239 View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 240 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 241 View 151-12 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 244 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 245 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 246 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 247 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 248 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 249 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 250 Engine Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 251 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 252 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 253 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 254 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 255 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 256 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 257 Engine Control Module: Connector Views C175B (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 258 C175B (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 259 C175B (Part 3) C175E (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 260 C175E (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 261 C175T (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 262 C175T (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The EEPROM is contained in an integrated circuit internal to the powertrain control module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle, and is capable of being programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate DTCs PI635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for DTC P1639. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block is displayed on the scan tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the scan tool displays a message indicating the need to flash the PCM again to reset the VID block. Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the scan tool manufacturer's instruction manual for details. Programming the VID Block for a Replacement PCM A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the VID block is blank and needs programming. There are 2 procedures available. The first is an automatic data transfer from the old PCM to the new PCM, and the second is manual data entry into the new PCM. Automatic data transfer is carried out if the old PCM is capable of communicating. This is done by using a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can then be downloaded to the new PCM after it has been installed. Carry out manual data entry if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible scan tool, select and carry out the module/parameter programming, referring to the scan tool manufacturer's instruction manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in DTCs P1635 and P1639. You may be instructed to contact the As-Built Data Center for the information needed to manually update the VID block with the scan tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and Lincoln Mercury technicians, contact your National Hotline or the Professional Technician Society (PTS) website for As-Built data listed under the Service Publications Index. Non-Ford technicians use the Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search function to find the Module Programming or As-Built Data. For Ford and Lincoln Mercury technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to Module Reprogramming on the scan tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production, or the need to reset the VID block because it has reached its limit. Refer to Module Reprogramming on the scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 265 Engine Control Module: Removal and Replacement POWERTRAIN CONTROL MODULE (PCM) Removal 1. NOTE: Any PCM replacement will require that ALL customer keys are available to be reprogrammed at the time of installation. PCM replacement DOES NOT require new keys. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation procedure. 2. Disconnect the PCM electrical connectors. 3. Remove the bolts and the PCM. 4. If necessary, remove the bolts and the PCM bracket. Installation 1. If necessary, install the PCM bracket and the bolts. - Tighten to 10 Nm (89 lb-in). 2. Install the PCM and the bolts. - Tighten to 7 Nm (62 lb-in). 3. Connect the PCM electrical connectors. 4. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation procedure. 5. Reprogram the passive anti-theft system (PATS). Carry out the Key Programming Using Two Programmed Keys procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 269 Main Relay (Computer/Fuel System): Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > EGR Control Module > Component Information > Locations EGR Control Module: Locations View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > EGR Control Module > Component Information > Locations > Page 274 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > EGR Control Module > Component Information > Locations > Page 275 C1450 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Locations View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Locations > Page 280 C433 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Locations > Page 281 Fuel Pump Control Unit: Service and Repair FUEL PUMP DRIVER MODULE (FPDM) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The fuel pump driver module (FPDM) is located above the spare tire. Disconnect the FPDM electrical connector. 3. Remove the FPDM bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 288 Main Relay (Computer/Fuel System): Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 293 View 151-22 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 294 Air Bag Control Module: Diagrams C310A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 295 C310B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 296 Air Bag Control Module: Service and Repair RESTRAINTS CONTROL MODULE (RCM) Removal WARNING: - If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. - Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: - When installing a new restraints control module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. - The air bag warning indicator illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Depower the SRS. 2. If equipped, remove the floor console. 3. If equipped, remove the 20 percent front seat cushion. Pull up to release the retainers on the 20 percent front seat cushion and remove. 4. Disconnect the RCM large electrical connector. 1 Pinch the thumb tab and pivot the connector position assurance lever all the way back until it stops. 2 Pull out and disconnect the RCM electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 297 5. Disconnect the RCM small electrical connector. 6. Remove the RCM bolts. 7. Remove the RCM. Installation 1. Position the RCM and install the bolts. - Tighten to 12 Nm (9 lb-ft). 2. Make sure the connector position assurance lever is in the full RELEASE position before attempting to connect the connector. 3. CAUTION: Putting the large restraints control module (RCM) electrical connector into the RCM on an angle can cause bad electrical connections and damage components. NOTE: The RCM has been removed for clarity. Position the large RCM electrical connector into the RCM. - CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the restraints control module (RCM) before using the lever to fully seat the connector. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and a slight resistance is felt. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 298 4. Connect the large RCM electrical connector. - Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. 5. Connect the RCM small electrical connector. 6. If equipped, install the floor console. 7. If equipped, install the 20 percent front seat cushion. Align the retainers on the 20 percent seat cushion and press down firmly near the front of the cushion to seat the retainers. 8. Repower the SRS. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations View 151-29 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 302 C3043 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 307 Starter Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 308 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Wheels and Tires > Tire Pressure Module > Component Information > Locations Tire Pressure Module: Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Wheels and Tires > Tire Pressure Module > Component Information > Locations > Page 314 View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Wheels and Tires > Tire Pressure Module > Component Information > Locations > Page 315 Tire Pressure Module: Diagrams C3008A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Wheels and Tires > Tire Pressure Module > Component Information > Locations > Page 316 C3008B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay Transfer Case Actuator Relay: Testing and Inspection Counter Clockwise (CCW) Motor 4X4 Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay > Page 323 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay > Page 324 Transfer Case Actuator Relay: Testing and Inspection Clockwise (CW) Motor 4X4 Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay > Page 325 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 330 Heated Glass Element Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 331 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left C4009 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 339 C4011 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 340 C4010 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 341 C4012 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 342 Parking Assist Distance Sensor: Service and Repair PARKING AID SENSOR Removal 1. Disconnect the parking aid sensor electrical connector. 2. Press the retaining tabs to remove the parking aid sensor. - Remove the parking aid sensor from the rear bumper. Installation 1. To install the parking aid sensor in the rear bumper, insert the sensor in the opening until the retaining tabs lock in position. 2. Connect the parking aid sensor electrical connector. 3. After installing the sensor(s), use the scan tool to verify that the parking aid sensor PIDs read no object present and that the parking aid sensor attenuation PIDs read between 0-16 ms. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Locations > Page 346 C2035 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Locations > Page 347 Parking Assist Switch: Service and Repair PARKING AID SWITCH Removal and Installation 1. Remove the instrument panel center finish panel. 2. Press the retaining tabs to remove the parking aid switch. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Diagrams C2090 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 354 C2235 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Diagrams C2090 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 362 C2235 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side View 151-31 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side > Page 367 View 151-30 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side C505 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side > Page 370 C605 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side Power Door Lock Switch: Testing and Inspection Door Lock Switch, Driver Side Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 373 Power Door Lock Switch: Testing and Inspection Door Lock Switch, Passenger Side Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Page 374 Power Door Lock Switch: Service and Repair DOOR LOCK CONTROL SWITCH Removal and Installation 1. Remove the switch plate cover. 2. Disconnect the switch plate electrical connectors. 3. Release the door lock control switch tabs on the switch plate and remove the door lock control switch. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations View 151-30 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 378 C527 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 379 Power Mirror Switch: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 380 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 381 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH Removal and Installation 1. Remove the front door switch panel. - Disconnect the electrical connectors. 2. Remove the exterior mirror control switch. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Sensor View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Sensor > Page 386 View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Sensor > Page 387 View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor C372 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 390 C383 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 391 C373 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Seat Control Switch, Driver Side Front View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Seat Control Switch, Driver Side Front > Page 396 View 151-29 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Passenger Side Front C330 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Passenger Side Front > Page 399 C369 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, Driver Side Front Power Seat Switch: Testing and Inspection Seat Control Switch, Driver Side Front Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, Driver Side Front > Page 402 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, Driver Side Front > Page 403 Power Seat Switch: Testing and Inspection Seat Control Switch, Passenger Side Front Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, Driver Side Front > Page 404 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair Seat Heater Switch: Service and Repair SEAT CONTROL SWITCH Exploded View Front Seat Backrest - With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Page 408 Front Seat Backrest - Without Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Page 409 Front Seat Cushion - Driver (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Page 410 Front Seat Cushion - Driver (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Page 411 Front Seat Cushion - Passenger (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Page 412 Front Seat Cushion - Passenger (Part 2) Removal and Installation 1. Disconnect the seat control switch electrical connector. 2. Remove the recliner handle. - Release the clip at the rear of side shield by detaching the clip from the metal bracket on the track. Partially flex the side shield at the rear to obtain access to the recliner handle clip. Remove the recliner handle clip (shown removed for clarity) and the recliner handle. 3. If equipped, remove the lumbar adjust knob. 4. Remove the seat control switch knob. 5. Remove the side shield control panel. 6. Remove the 2 screws and the seat control switch. 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 416 C3246 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations View 151-35 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 420 C912 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 421 Sunroof / Moonroof Switch: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 422 Sunroof / Moonroof Switch: Service and Repair ROOF OPENING PANEL CONTROL SWITCH Removal and Installation 1. Remove the overhead console. 2. Disconnect the 2 overhead console electrical connectors. 3. Remove the 4 screws and light assembly from the overhead console. 4. Disengage the clips and remove the switch from the overhead console. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 423 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations View 151-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 428 C124 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations > Page 432 C455 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 436 C2015 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 437 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the parking brake warning indicator switch electrical connector. 3. Remove the parking brake warning indicator switch screw and the switch. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations View 151-14 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 441 C280 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front View 151-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 446 View 151-2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front C150 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 449 C160 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor - Front, Rear Wheel Drive (RWD) Wheel Speed Sensor - Front, Rear Wheel Drive (RWD) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. NOTE: The harness connector is located in the engine compartment secured to the fender apron. Disconnect the wheel speed sensor electrical connector. 3. Disconnect the 2 wheel speed sensor harness retainers from the brake hose. 4. Remove the wheel speed sensor harness from the pushpin retainer. 5. Remove the bolt and the wheel speed sensor. ^ To install, tighten to 8 Nm (71 lb-in). 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 452 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Disconnect the wheel speed sensor electrical connector. 3. Remove the wheel speed sensor bolt. ^ To install, tighten to 15 Nm (11 lb-ft). 4. NOTE: Install a new O-ring before installing the rear axle speed sensor. Remove the wheel speed sensor. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Radiator Cooling Fan Speed Sensor > Component Information > Description and Operation Radiator Cooling Fan Speed Sensor: Description and Operation FAN SPEED SENSOR (FSS) Cooling Fan Clutch With FSS The FSS is a Hall-effect sensor that measures the cooling fan clutch speed by generating a waveform with a frequency proportional to the fan speed. If the cooling fan clutch is moving at a relatively low speed, the sensor produces a signal with a low frequency. As the cooling fan clutch speed increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the FSS as a feedback for closed loop control of the cooling fan clutch. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 461 C107 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 462 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 463 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Remove the generator. 2. Disconnect the cylinder head temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. - Apply anti-seize to the threads of the CHT sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 469 View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch C277 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 472 C278 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 473 Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Brake Pedal Switch (BPS)/Brake Deactivator Switch The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is not applied. When the brake pedal is applied, the normally closed switch opens and power is removed from the PCM. On some applications the normally closed BPS, along with the normally open BPP switch, are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not changing states when they were expected to, a diagnostic trouble code (DTC) is set by the PCM strategy. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 474 Brake Switch (Cruise Control): Service and Repair SPEED CONTROL DEACTIVATOR SWITCH Removal and Installation 1. CAUTION: Do not press the brake pedal when removing or installing the speed control deactivator switch or damage to the switch will occur. Disconnect the speed control deactivator switch electrical connector. 2. Rotate the speed control deactivator switch counterclockwise 45 degrees and remove it. 3. NOTE: The speed control deactivator switch is self-adjusting. Do not press the brake pedal during installation. Initial installation of the speed control deactivator switch allows for one adjustment. If additional adjustments are necessary, install a new speed control deactivator switch. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 478 C257 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 479 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations View 151-20 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Without Remote Audio/Climate Controls Cruise Control Switch: Service and Repair Speed Control Switch - Without Remote Audio/Climate Controls SPEED CONTROL SWITCH - WITHOUT REMOTE AUDIO/CLIMATE CONTROLS Removal and Installation 1. Remove the steering wheel. 2. Remove the steering wheel base cover. 3. Disconnect the speed control switches electrical connectors. 4. Remove the 4 nuts and the speed control switches. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Without Remote Audio/Climate Controls > Page 485 Cruise Control Switch: Service and Repair Speed Control Switch - With Remote Audio/Climate Controls SPEED CONTROL SWITCH - WITH REMOTE AUDIO/CLIMATE CONTROLS Removal and Installation 1. Remove the steering wheel. 2. Remove the steering wheel base cover. 3. Disconnect the speed control switch electrical connector. 4. Remove the 2 nuts and the speed control switch. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 490 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 491 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 492 C103 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 493 Oil Pressure Sender: Service and Repair Engine Oil Pressure (EOP) Switch Engine Oil Pressure (EOP) Switch Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the engine oil pressure (EOP) switch. ^ To install, tighten to 18 Nm (13 lb-ft). 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Description and Operation Oil Temperature Sensor/Switch: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Locations View 151-20 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations View 151-2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 504 C132 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 505 In-Vehicle Temperature Sensor - HVAC Module - Electronic Automatic Temperature Control (EATC) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations View 151-18 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 509 C271 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 510 Blower Motor Switch: Description and Operation BLOWER MOTOR SWITCH The blower motor switch is mounted in the HVAC module and controls blower motor speed by adding or bypassing resistors in the blower motor resistor in all function selector switch positions except OFF. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 511 Blower Motor Switch: Service and Repair BLOWER MOTOR SPEED CONTROL Removal and Installation 1. NOTE: The blower motor speed control can be accessed from below the RH side of the instrument panel. Disconnect the blower motor speed control electrical connector. 2. Remove the blower motor speed control screw. 3. Detach the blower motor speed control. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 515 C233 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 516 Cabin Temperature Sensor / Switch: Service and Repair IN-VEHICLE TEMPERATURE SENSOR Removal and Installation 1. Remove the instrument cluster finish panel. 2. Remove the 2 in-vehicle temperature sensor screws. 3. Remove the temperature sensor finish panel. 4. Remove the in-vehicle temperature sensor. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) SENSOR A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance The ACET sensor measures the evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance changes the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improve defrost/demist performance, and reduce A/C clutch cycling. NOTE: These values can vary 15% due to sensor and VREF variations. Voltage values were calculated for VREF equals 5.0 volts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations View 151-2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Cycling Switch C130 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Cycling Switch > Page 525 C1260 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch A/C CYCLING SWITCH The A/C cycling switch is mounted on a Schrader valve-type fitting on the suction accumulator. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction pressure to control the operation of the A/C cycling switch. - Battery voltage is present at one side of the A/C cycling switch at all times when the ignition switch is in the RUN position. - When the switch contacts are closed, the battery voltage circuit is completed to the PCM to signal that the low-side refrigerant system pressure is acceptable for A/C compressor operation. - When the switch contacts are open, the battery voltage circuit is opened to signal the PCM that the low-side refrigerant system pressure is too low for A/C compressor operation. - The A/C cycling switch will control the evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the evaporator core and blockage of airflow. - It is not necessary to recover the refrigerant to remove the A/C cycling switch. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 528 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) Cycling Switch Air Conditioning (A/C) Cycling Switch The A/C cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C cycling switch opens, the PCM turns off the A/C clutch. For information on the specific function of the A/C cycling switch, refer to Heating and Air Conditioning, Climate Control System Air Conditioning System Overview. Also, refer to the applicable Vehicle/Diagrams for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. Some applications do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the communication link. Air Conditioning (A/C) High Pressure Switch The A/C high pressure switch is used for additional A/C system pressure control. The A/C high pressure switch is either dual function for multiple speed, relay controlled electric fan applications, or single function for all others. For refrigerant containment control, the normally closed high pressure contacts open at a predetermined A/C pressure. This results in the A/C turning off, preventing the A/C pressure from rising to a level that would open the A/C high pressure relief valve. For fan control, the normally open medium pressure contacts close at a predetermined A/C pressure. This grounds the ACPSW circuit input to the PCM. The PCM then turns on the high speed fan to help reduce the pressure. For additional information, refer to Heating and Air Conditioning, Climate Control System, Air Conditioning System Overview or Vehicle/Diagrams. Air Conditioning Pressure (ACP) Transducer Sensor A/C Pressure Transducer Sensor Output Voltage Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 529 Typical ACP Transducer Sensor The ACP transducer sensor is located in the high pressure (discharge) side of the A/C system. The ACP transducer sensor provides a voltage signal to the PCM that is proportional to the A/C pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 533 C286 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Left Front View 151-30 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Left Front > Page 539 View 151-31 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Left Front > Page 540 View 151-33 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front C526 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 543 C602 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 544 C715 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 545 C820 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 546 Door Switch: Service and Repair DOOR AJAR SWITCH Removal and Installation 1. Remove the front or rear door latch. 2. Release the locking tab and remove the door ajar switch. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-2-9 > Feb > 08 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 Fuel Gauge Sender: Customer Interest Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 TSB 08-2-9 02/04/08 ERRATIC FUEL GAUGE OPERATION - MIL ON - DTCS P0460/P0463 OR INSTRUMENT CLUSTER MODULE DTC B1201 - VEHICLES BUILT BEFORE 12/3/2007 FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT vehicles, built before 12/3/2007, may exhibit erratic fuel gauge operation or illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P0460 or P0463, and/or Instrument Cluster Module DTC B1201. This may be caused by sulphur contamination in the fuel causing an open or high resistance in the fuel level sender. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Install a new fuel level sender following the service procedure instruction sheet provided in the fuel sender kit. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 080209A 2004-2008 F-150, 1.9 Hrs. 2006-2008 Mark LT: Install New Fuel Level Sender, Includes Time To Remove Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-2-9 > Feb > 08 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 > Page 555 And Install Fuel Tank (Do Not Use With 9002A, 9002A4, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-2-9 > Feb > 08 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 TSB 08-2-9 02/04/08 ERRATIC FUEL GAUGE OPERATION - MIL ON - DTCS P0460/P0463 OR INSTRUMENT CLUSTER MODULE DTC B1201 - VEHICLES BUILT BEFORE 12/3/2007 FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT vehicles, built before 12/3/2007, may exhibit erratic fuel gauge operation or illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P0460 or P0463, and/or Instrument Cluster Module DTC B1201. This may be caused by sulphur contamination in the fuel causing an open or high resistance in the fuel level sender. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Install a new fuel level sender following the service procedure instruction sheet provided in the fuel sender kit. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 080209A 2004-2008 F-150, 1.9 Hrs. 2006-2008 Mark LT: Install New Fuel Level Sender, Includes Time To Remove Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-2-9 > Feb > 08 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 > Page 561 And Install Fuel Tank (Do Not Use With 9002A, 9002A4, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 562 View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 563 Fuel Gauge Sender: Diagrams C4074 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 564 C4330 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 565 Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 566 The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Fuel Pump (FP) Module and Reservoir The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module Fuel Gauge Sender: Service and Repair Fuel Pump Module FUEL PUMP MODULE Special Tool(s) Special Tool(s) Removal WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 569 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the fuel tank. 3. Using soapy water, clean a minimum of 76 mm (3 in) surface area around the fuel pump module. 4. Disconnect the fuel supply and fuel vapor tube assembly quick connect couplings at the fuel pump module and remove the fuel supply and fuel vapor tube assembly from the fuel tank. 5. Using the special tool, remove the fuel pump module locking ring. 6. Lift the fuel pump module out of the fuel tank enough to disconnect the internal fuel tank grade vent valves-to-fuel pump quick connect coupling. 7. CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter. Remove the fuel pump module. 8. Remove and discard the fuel pump module O-ring seal. Installation 1. NOTE: Lubricate the new fuel pump module O-ring seal with clean engine oil prior to installation. Install a new fuel pump module O-ring seal. 2. CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter. Install the fuel pump module into the fuel tank enough to connect the internal fuel tank grade vent valves-to-fuel pump quick connect coupling. 3. Install the fuel pump module the rest of the way into the fuel tank. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 570 4. Using the special tool, install the fuel pump module locking ring. 5. NOTE: - The fuel pump module does not come equipped with a fuel pump module cover from the factory. The fuel pump module cover is only installed after service to the fuel pump module is performed. - Before installing the fuel pump module cover, make sure it fits around all fuel and vapor ports and electrical connectors and allows enough clearance to install the fuel and vapor tube assembly and the fuel pump module electrical connector. - Make sure a minimum of 76 mm (3 in) surface area is properly cleaned of all gas, oil and foreign material before installing the fuel pump module cover. Install a fuel pump module cover over the fuel pump module and locking ring. 6. Install the fuel supply and fuel vapor tube assembly onto the fuel tank and connect the fuel supply and fuel vapor tube assembly quick connect couplings at the fuel pump module. 7. Install the fuel tank. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 571 Fuel Gauge Sender: Service and Repair Fuel Level Sender FUEL LEVEL SENDER Removal WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. 1. Remove the fuel pump module. 2. NOTE: Note the routing of the fuel level sender wire for installation. Unwrap the fuel level sender wire from the rest of the fuel pump module wire harness. 3. Remove the heat shrink tube covering the electrical connector. 4. Disconnect the electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 572 5. NOTE: Gasoline shown, flexible fuel similar. Remove the screw and lift up to remove the fuel level sender. Installation All vehicles 1. Route the fuel level sender wire through the center of the fuel pump module. Gasoline vehicles 2. NOTE: - Both fuel level sender wires must be routed behind the metal fuel level sender plate. - The grounding eyelet must be on the front side of the fuel level sender. Hook the fuel level sender on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. Flexible fuel vehicles Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 573 3. NOTE: - One fuel level sender wire routes behind the fuel level sender and one routes along the left side of the fuel level sender. - The grounding eyelet must be on the front side of the fuel level sender. Hook the fuel level sender on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. Clip the wire into the clip on the fuel pump module. All vehicles 4. Slide the heat shrink tube onto the wire harness and connect the electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, heat the heat shrink tube. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 574 6. Wrap the fuel level sender wire around the fuel pump module wire harness to make sure the wire will not interfere with the movement of the fuel gauge sending unit float arm. 7. Install the fuel pump module. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 578 C2015 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 579 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the parking brake warning indicator switch electrical connector. 3. Remove the parking brake warning indicator switch screw and the switch. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 584 C286 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 585 Ambient Light Sensor: Service and Repair LIGHT SENSOR Removal and Installation 1. Remove the defroster grille panel. - Disconnect the electrical connector. 2. Remove the 2 screws and the light sensor. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Reversing Lamps Switch View 151-12 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Reversing Lamps Switch > Page 590 Backup Lamp Switch: Locations Digital Transmission Range (DTR) Sensor View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Reversing Lamps Switch > Page 591 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Digital Transmission Range (DTR) Sensor C167 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Digital Transmission Range (DTR) Sensor > Page 594 C169 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 598 C278 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 599 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 600 Brake Light Switch: Service and Repair STOPLAMP SWITCH Removal and Installation 1. Disconnect the battery. 2. Disconnect the stoplamp switch electrical connector. 3. Remove the retainer. 4. Remove the pin. 5. Remove the stoplamp switch. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Left Front View 151-30 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Left Front > Page 605 View 151-31 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Left Front > Page 606 View 151-33 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front C526 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 609 C602 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 610 C715 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 611 C820 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 612 Door Switch: Service and Repair DOOR AJAR SWITCH Removal and Installation 1. Remove the front or rear door latch. 2. Release the locking tab and remove the door ajar switch. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection Hazard Warning Switch: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 616 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations View 151-19 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 620 Headlamp Dimmer Switch: Diagrams C202A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 621 C202B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 622 C202C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 623 Headlamp Dimmer Switch: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 627 Headlamp Switch: Diagrams C2150A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 628 C2150B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps Headlamp Switch: Testing and Inspection Main Light Switch, Exterior Lamps Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 631 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 632 Headlamp Switch: Testing and Inspection Main Light Switch, Interior Lamps Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Page 633 Headlamp Switch: Service and Repair HEADLAMP SWITCH Removal and Installation 1. Remove the headlamp switch. - Disconnect the headlamp switch electrical connector. 2. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations View 151-20 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations View 151-19 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 640 Turn Signal Switch: Diagrams C202A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 641 C202B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 642 C202C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion Turn Signal Switch: Testing and Inspection Multifunction Switch, Lamp Portion Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 645 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 646 Turn Signal Switch: Testing and Inspection Multifunction Switch, Turn Portion Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 647 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 648 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch Steering Column Multifunction Switch Removal and Installation 1. Remove the steering wheel. 2. Remove the lower steering column shroud screw. 3. Apply inward pressure to the upper and lower shroud cover seam and remove the lower shroud. 4. Remove the 2 screws and the upper steering column shroud. 5. Remove the screw, release the tab and position the multi-function switch aside. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 649 6. Disconnect the multi-function switch electrical connector. 7. Remove the multi-function switch. 8. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 655 C2251 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 656 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor 2-Track APP Sensor There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are 2 reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 3-Track APP Sensor Typical 3-Track APP Sensor There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APP2 and APP3, both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 660 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 661 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 662 C1454 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 663 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 664 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 665 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Open the clamp on the air cleaner and separate the tray from the cover. 2. Disconnect the mass air flow (MAF) sensor electrical connector and detach the connector retainer. 3. Remove the grommet from the air cleaner cover and slide it down the electrical harness. 4. Pull the air cleaner inner cover and MAF sensor out of the air cleaner cover. 5. Disconnect the MAF sensor electrical connector and remove the inner cover and MAF sensor assembly. 6. Remove the bolts and the MAF sensor. - To install, tighten to 2 Nm (18 lb-in). 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 670 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 671 Camshaft Position Sensor: Locations Camshaft Position Sensor View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 672 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor Camshaft Position Sensor: Diagrams Camshaft Position Sensor C180 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 675 C1180 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 676 C1366 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 677 C1367 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 678 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil on plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 679 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the camshaft position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. - Lubricate the CMP sensor O-ring seal with clean engine oil prior to installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 683 C257 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 684 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 685 Clutch Switch: Service and Repair CLUTCH PEDAL POSITION (CPP) SWITCH Removal and Installation 1. Disconnect the clutch pedal position (CPP) switch electrical connector. 2. Detach the pushrod from the clutch lever pin. 3. Remove the CPP switch. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 689 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 690 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 691 C101 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 692 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 693 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Rotate the accessory drive belt clockwise and detach the accessory drive belt from the A/C compressor pulley. 3. Loosen the A/C compressor bolts enough to slide the A/C compressor down approximately 25 mm (1 in), to allow access to the crankshaft position (CKP) sensor. To install, tighten to 25 Nm (18 lb-ft). 4. Disconnect the CKP sensor electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 694 5. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 6. To install, reverse the removal procedure. - Lubricate the O-ring seal with clean engine oil prior to installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 698 C107 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 699 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 700 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Remove the generator. 2. Disconnect the cylinder head temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. - Apply anti-seize to the threads of the CHT sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL INPUT (FLI) The FLI is a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module Fuel Level Sensor: Service and Repair Fuel Pump Module FUEL PUMP MODULE Special Tool(s) Special Tool(s) Removal WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 706 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the fuel tank. 3. Using soapy water, clean a minimum of 76 mm (3 in) surface area around the fuel pump module. 4. Disconnect the fuel supply and fuel vapor tube assembly quick connect couplings at the fuel pump module and remove the fuel supply and fuel vapor tube assembly from the fuel tank. 5. Using the special tool, remove the fuel pump module locking ring. 6. Lift the fuel pump module out of the fuel tank enough to disconnect the internal fuel tank grade vent valves-to-fuel pump quick connect coupling. 7. CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter. Remove the fuel pump module. 8. Remove and discard the fuel pump module O-ring seal. Installation 1. NOTE: Lubricate the new fuel pump module O-ring seal with clean engine oil prior to installation. Install a new fuel pump module O-ring seal. 2. CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter. Install the fuel pump module into the fuel tank enough to connect the internal fuel tank grade vent valves-to-fuel pump quick connect coupling. 3. Install the fuel pump module the rest of the way into the fuel tank. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 707 4. Using the special tool, install the fuel pump module locking ring. 5. NOTE: - The fuel pump module does not come equipped with a fuel pump module cover from the factory. The fuel pump module cover is only installed after service to the fuel pump module is performed. - Before installing the fuel pump module cover, make sure it fits around all fuel and vapor ports and electrical connectors and allows enough clearance to install the fuel and vapor tube assembly and the fuel pump module electrical connector. - Make sure a minimum of 76 mm (3 in) surface area is properly cleaned of all gas, oil and foreign material before installing the fuel pump module cover. Install a fuel pump module cover over the fuel pump module and locking ring. 6. Install the fuel supply and fuel vapor tube assembly onto the fuel tank and connect the fuel supply and fuel vapor tube assembly quick connect couplings at the fuel pump module. 7. Install the fuel tank. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 708 Fuel Level Sensor: Service and Repair Fuel Level Sender FUEL LEVEL SENDER Removal WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. 1. Remove the fuel pump module. 2. NOTE: Note the routing of the fuel level sender wire for installation. Unwrap the fuel level sender wire from the rest of the fuel pump module wire harness. 3. Remove the heat shrink tube covering the electrical connector. 4. Disconnect the electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 709 5. NOTE: Gasoline shown, flexible fuel similar. Remove the screw and lift up to remove the fuel level sender. Installation All vehicles 1. Route the fuel level sender wire through the center of the fuel pump module. Gasoline vehicles 2. NOTE: - Both fuel level sender wires must be routed behind the metal fuel level sender plate. - The grounding eyelet must be on the front side of the fuel level sender. Hook the fuel level sender on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. Flexible fuel vehicles Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 710 3. NOTE: - One fuel level sender wire routes behind the fuel level sender and one routes along the left side of the fuel level sender. - The grounding eyelet must be on the front side of the fuel level sender. Hook the fuel level sender on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. Clip the wire into the clip on the fuel pump module. All vehicles 4. Slide the heat shrink tube onto the wire harness and connect the electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, heat the heat shrink tube. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 711 6. Wrap the fuel level sender wire around the fuel pump module wire harness to make sure the wire will not interfere with the movement of the fuel gauge sending unit float arm. 7. Install the fuel pump module. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 715 C435 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 716 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE (FTP) SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 720 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 721 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 722 C1454 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 723 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type MAF Sensor The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 724 fuel, spark, and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described above. One is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control spark and to help determine charge air cooler (CAC) efficiency. Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 725 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 730 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 731 Knock Sensor: Locations Knock Sensor View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 732 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 C109 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 735 C108 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 736 Knock Sensor: Diagrams Knock Sensor C1512 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 737 C1514 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 738 Knock Sensor: Description and Operation Knock Sensor (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 739 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Typical Manifold Absolute Pressure (MAP) Sensor The MAP sensor measures intake manifold absolute pressure. The PCM uses information from the MAP sensor to measure how much exhaust gas is introduced into the intake manifold. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation > Page 746 Oil Temperature Sensor For ECM: Service and Repair OIL TEMPERATURE SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the oil drain plug and drain the engine oil. - To install, tighten to 23 Nm (17 lb-ft). 3. Disconnect the oil temperature sensor electrical connector. 4. Remove the oil temperature sensor. - To install, tighten to 21 Nm (15 lb-ft). 5. To install, reverse the removal procedure. - Inspect the oil temperature O-ring seal and install a new O-ring seal if necessary. - Fill the engine with clean engine oil. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #11/#21 View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 751 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 752 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 753 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12/#22 View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 754 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 755 View 151-12 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 C141 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 758 C142 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 759 C171 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 760 C172 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 761 Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Heated Oxygen Sensor (HO2S) The HO2S detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by providing the ground when the correct conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Universal HO2S The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner, the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio. The measured air/fuel ratio is actually the output from the current controller in the PCM and not a signal that comes directly from the sensor. The universal HO2S also uses a self-contained reference chamber to make sure an oxygen differential is always present. The oxygen for the reference chamber is supplied by pumping small amounts of oxygen ions from the measurement chamber into the reference chamber. The universal HO2S does not need access to outside air. Part to part variance is compensated for by placing a resistor in the connector. This resistor is used to trim the current measured by the current controller in the PCM. Embedded with the sensing element is the universal H02S heater. The heater allows the engine to enter closed loop operation sooner. The heating element heats the sensor to a temperature of 780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on and off by providing the ground to maintain the sensor at the correct temperature for maximum accuracy. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) HEATED OXYGEN SENSOR (HO2S) Exploded View Special Tool(s) Special Tool(s) Removal And Installation 1. With the vehicle in NEUTRAL, position it on a hoist. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 764 2. NOTE: If necessary, lubricate the heated oxygen sensor (HO2S) with penetrating and lock lubricant to assist in removal Using the special tool, remove the HO2S. To install, tighten to 46 Nm (34 lb-ft). 3. To install, reverse the removal procedure. - Apply anti-seize to the threads of the HO2S. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 765 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 766 2. NOTE: If necessary, lubricate the catalyst monitor sensor with penetrating and lock lubricant to assist in removal. Using the special tool, remove the catalyst monitor sensor. To install, tighten to 46 Nm (34 lb-ft). 3. To install, reverse the removal procedure. - Apply anti-seize to the threads of the catalyst monitor sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 770 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 771 C1311 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 772 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example, during parking maneuvers. Power Steering Pressure (PSP) Switch Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback EGR sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 776 The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 777 Pressure Feedback Exhaust Sensor: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal 1. Disconnect the EGR system module electrical connector. 2. Disconnect the EGR system module vacuum connector. 3. Disconnect the exhaust manifold-to-EGR system module tube from the EGR system module. 4. Remove the bolts, the EGR system module and the gasket. Discard the gasket. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old gasket. Clean the EGR system module gasket mating surfaces. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 778 2. Install a new gasket with the raised circle facing the throttle body (TB) adapter. 3. Position the EGR system module and install the bolts. - Tighten to 25 Nm (18 lb-ft). 4. Connect the exhaust manifold-to-EGR system module tube the EGR system module. - Tighten to 40 Nm (30 lb-ft). 5. Connect the EGR system module vacuum connector. 6. Connect the EGR system module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 782 C189 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 783 Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The 2 ETB throttle position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. Throttle Position (TP) Sensor Typical TP Sensor The TP sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a 3-blade electrical connector that may be gold plated. The gold plating increases the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating conditions are: closed throttle (includes idle or deceleration) - part throttle (includes cruise or moderate acceleration) - wide open throttle (includes maximum acceleration or de-choke on crank) - throttle angle rate Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 Transmission Position Switch/Sensor: Locations View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 787 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 790 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 791 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 792 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 793 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 794 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 795 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 796 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 797 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 798 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 799 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 800 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 801 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 802 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 803 C167 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 804 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the selector lever cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 4. Loosen the digital transmission range (TR) sensor bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 805 5. NOTE: The manual control lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 lb-in). 7. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever shaft outer nut. ^ Tighten to 33 Nm (24 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 806 8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. With the manual control lever in overdrive connect the selector lever cable. 9. Lower the vehicle. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 807 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Removal NOTE: The manual control lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the selector lever cable. Disconnect the selector lever cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 808 3. Disconnect the digital transmission range (TR) electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 809 Installation 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 810 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 lb-ft). 5. Connect the digital TR sensor electrical connector. 6. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable end to the manual control lever with the lever in the (D) position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 811 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor The OSS sensor provides the PCM with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information that is generated. Vehicle Speed Sensor (VSS) Typical Vehicle Speed Sensor (VSS) The VSS is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling, and torque converter clutch scheduling. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback EGR sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 819 The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 820 Pressure Feedback Exhaust Sensor: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal 1. Disconnect the EGR system module electrical connector. 2. Disconnect the EGR system module vacuum connector. 3. Disconnect the exhaust manifold-to-EGR system module tube from the EGR system module. 4. Remove the bolts, the EGR system module and the gasket. Discard the gasket. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old gasket. Clean the EGR system module gasket mating surfaces. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 821 2. Install a new gasket with the raised circle facing the throttle body (TB) adapter. 3. Position the EGR system module and install the bolts. - Tighten to 25 Nm (18 lb-ft). 4. Connect the exhaust manifold-to-EGR system module tube the EGR system module. - Tighten to 40 Nm (30 lb-ft). 5. Connect the EGR system module vacuum connector. 6. Connect the EGR system module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Locations > Page 826 C2251 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Locations > Page 827 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor 2-Track APP Sensor There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are 2 reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 3-Track APP Sensor Typical 3-Track APP Sensor There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APP2 and APP3, both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 831 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 832 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 833 C1454 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 834 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 835 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 836 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Open the clamp on the air cleaner and separate the tray from the cover. 2. Disconnect the mass air flow (MAF) sensor electrical connector and detach the connector retainer. 3. Remove the grommet from the air cleaner cover and slide it down the electrical harness. 4. Pull the air cleaner inner cover and MAF sensor out of the air cleaner cover. 5. Disconnect the MAF sensor electrical connector and remove the inner cover and MAF sensor assembly. 6. Remove the bolts and the MAF sensor. - To install, tighten to 2 Nm (18 lb-in). 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Fuel Pressure Sensor/Switch: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 840 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 841 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 842 Fuel Pressure Sensor/Switch: Diagrams C173 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 843 C1475 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 844 Fuel Pressure Sensor/Switch: Description and Operation FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 845 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the fuel pressure and temperature sensor electrical connector. 3. Disconnect the fuel pressure and temperature sensor vacuum connector. 4. Remove the bolts and the fuel pressure and temperature sensor. - To install, tighten to 4 Nm (35 lb-in). 5. Remove and discard the O-ring seal. - Install a new O-ring seal and lubricate with clean engine oil prior to installation. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Temperature Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 849 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 850 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 851 Fuel Temperature Sensor: Diagrams C173 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 852 C1475 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 853 Fuel Temperature Sensor: Description and Operation FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 854 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the fuel pressure and temperature sensor electrical connector. 3. Disconnect the fuel pressure and temperature sensor vacuum connector. 4. Remove the bolts and the fuel pressure and temperature sensor. - To install, tighten to 4 Nm (35 lb-in). 5. Remove and discard the O-ring seal. - Install a new O-ring seal and lubricate with clean engine oil prior to installation. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-18 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 858 C282 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 859 Inertia Fuel Shutoff Switch: Description and Operation INERTIA FUEL SHUTOFF (IFS) SWITCH Typical Inertia Fuel Shutoff (IFS) Switch The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shutoff the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner's Literature, Roadside Emergencies for the location of the IFS switch. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 860 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. Remove the RH cowl side trim panel. 2. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 3. Remove the 2 IFS bolts and the IFS switch. - To install, tighten to 2 Nm (18 lb-in). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 864 C189 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 865 Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The 2 ETB throttle position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. Throttle Position (TP) Sensor Typical TP Sensor The TP sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a 3-blade electrical connector that may be gold plated. The gold plating increases the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating conditions are: closed throttle (includes idle or deceleration) - part throttle (includes cruise or moderate acceleration) - wide open throttle (includes maximum acceleration or de-choke on crank) - throttle angle rate Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 871 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 872 Camshaft Position Sensor: Locations Camshaft Position Sensor View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 873 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor Camshaft Position Sensor: Diagrams Camshaft Position Sensor C180 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 876 C1180 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 877 C1366 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 878 C1367 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 879 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil on plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 880 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the camshaft position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. - Lubricate the CMP sensor O-ring seal with clean engine oil prior to installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 884 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 885 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 886 C101 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 887 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 888 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Rotate the accessory drive belt clockwise and detach the accessory drive belt from the A/C compressor pulley. 3. Loosen the A/C compressor bolts enough to slide the A/C compressor down approximately 25 mm (1 in), to allow access to the crankshaft position (CKP) sensor. To install, tighten to 25 Nm (18 lb-ft). 4. Disconnect the CKP sensor electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 889 5. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 6. To install, reverse the removal procedure. - Lubricate the O-ring seal with clean engine oil prior to installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Part 1 Part 2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Page 894 Removal and Installation NOTE: - When a new lock cylinder is installed, the tailgate lock cylinder, door lock cylinders and the ignition lock cylinder should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is to be used, the new key code is attached to a tag. - The individual door lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build a new lock cylinder to the current key code of the vehicle. 1. Remove the steering wheel. 2. Remove bolt and the lower steering column shroud. 3. NOTE: The steering column shift is shown, the floor console shift is similar. Position the ignition lock cylinder cover aside. 4. Disconnect the PATS transceiver electrical connector. 5. Remove the screw and the PATS transceiver. 6. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove the lock cylinder. 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 899 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 900 Knock Sensor: Locations Knock Sensor View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 901 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 C109 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 904 C108 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 905 Knock Sensor: Diagrams Knock Sensor C1512 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 906 C1514 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 907 Knock Sensor: Description and Operation Knock Sensor (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 908 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations View 151-2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 913 C177 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 914 Impact Sensor: Testing and Inspection IMPACT SENSORS WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. For this vehicle line, the SRS uses one satellite sensor in addition to the RCM. The RCM is mounted to the center tunnel beneath the 20 percent seat or floor console (if equipped). All vehicles have one front impact severity sensor located in the front-center area of the vehicle, behind the grille mounted on the lower radiator support. Mounting orientation is critical for correct operation of all impact sensors. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 915 Impact Sensor: Service and Repair FRONT IMPACT SEVERITY SENSOR Removal and Installation WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: - The supplemental restraint system (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Depower the SRS. 2. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. CAUTION: If the hood latch support bracket is damaged in any way that would affect the way the front impact severity sensor mounts to its original manufactured position, a new hood latch support bracket must be installed. NOTE: The front impact severity sensor is mounted to the hood latch support bracket. Remove the front impact severity sensor bolt. To install, tighten to 12 Nm (9 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 916 3. NOTE: Make sure the hood latch support bracket and front impact severity sensor mating surfaces are clean and free of foreign material. Remove the front impact severity sensor and disconnect the electrical connector. When installing the front impact severity sensor, align the locators on the front impact severity sensor to the holes of the hood latch bracket. 4. To install, reverse the removal procedure. 5. Repower the SRS. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger View 151-29 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 921 View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver C3065 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 924 C3066 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Tension Sensor > Component Information > Description and Operation Seat Belt Tension Sensor: Description and Operation BELT TENSION SENSOR (BTS) The safety belt tension sensor (BTS) is part of the passenger front outboard safety belt and retractor assembly and is not serviced separately. The safety BTS is located at the safety belt anchor point and is used in conjunction with the occupant classification sensor (OCS) system. Refer to Air Bag Systems. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations View 151-29 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Page 931 C3042 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Page 932 Seat Occupant Sensor: Description and Operation OCCUPANT CLASSIFICATION SENSOR (OCS) WARNING: Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. NOTE: - Occupant classification sensor (OCS) system components (set wiring harness, seat cushion frame, seat cushion foam pad, bladder with pressure sensor and occupant classification system module [OCSM]) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, an OCS system service kit (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness and OCSM) must be installed as an assembly. - To identify between a production OCS system and an OCS system service kit, inspect the OCSM electrical connector. A production OCS system allows the disconnection of the OCSM electrical connector. An OCS system service kit has the electrical connector glued to the OCSM, it cannot and should not be disconnected or altered. The OCS system is standard equipment on all front outboard passenger seats. For information on diagnosing or servicing the OCS system, refer to Air Bag Systems. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Page 933 Seat Occupant Sensor: Service and Repair OCCUPANT CLASSIFICATION SENSOR Special Tool(s) Special Tool(s) Removal WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Page 934 CAUTION: - While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - To prevent system failure, it is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. - Do not install a new heater mat on a front passenger seat cushion. If a new cushion heater mat is needed on the front passenger seat, an occupant classification sensor (OCS) service kit equipped with a heater mat must be installed. Failure to follow this instruction may result in incorrect operation of the OCS system. NOTE: - Occupant classification sensor (OCS) system components (seat wiring harness, seat cushion frame, seat cushion foam pad, bladder with pressure sensor and occupant classification system module [OCSM]) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, an OCS system service kit (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness and OCSM) must be installed as an assembly. - To identify between a production OCS system and an OCS service kit, inspect the OCSM electrical connector. A production OCS system allows the disconnect of the electrical connector from the OCSM. An OCS system service kit has the OCSM electrical connector glued to the module. It cannot and should not be disconnected or altered. - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Remove the passenger seat. 2. CAUTION: To prevent component damage and avoid setting DTCs, the following precautions must be taken when disconnecting the safety belt buckle pretensioner. The position assurance locking wedge must be in the released position when inserting or removing the electrical connector from the safety belt buckle and pretensioner. - Do not install the electrical connector by pushing on the position assurance locking wedge. - Make sure the electrical connector and position assurance locking wedge are fully seated after connecting to the safety belt buckle and pretensioner. Release the locking wedge on the safety belt buckle and pretensioner electrical connector. 3. Disconnect the safety belt buckle switch and pretensioner electrical connectors. 4. NOTE: Vehicles without seat integrated restraints (SIR) will have the belt tension sensor (BTS) connector at the B-pillar and will not have to be disconnected for this procedure. Disconnect the BTS electrical connector and route out the wire harness (vehicles with SIR only). 5. Remove the seat cushion nuts. 6. If equipped with manual lumbar, release the J-clip and route out the manual lumbar cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Page 935 7. NOTE: Disconnect and release any remaining electrical connectors and pin-type retainers necessary to remove the seat cushion frame. Remove the seat cushion frame assembly. To aid in removal, recline the seat. - Remove the safety belt buckle from the seat cushion strap. 8. Release the seat cushion trim cover J-clips and pin-type retainers from the seat cushion frame. 9. At the front outboard side of the seat cushion frame, pull the trim cover back and release the 2 remaining clips. 10. Remove all the hog rings and separate the trim cover from the foam pad of the OCS assembly. Installation CAUTION: - While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - To prevent system failure, it is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. - Do not install a new heater mat on a front passenger seat cushion. If a new cushion heater mat is needed on the front passenger seat, an occupant classification sensor (OCS) service kit equipped with a heater mat must be installed. Failure to follow this instruction may result in incorrect operation of the OCS system. NOTE: OCS system components (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness and OCSM) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or cushion foam pad are needed, an OCS system service kit (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness and OCSM) must be installed as an assembly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Page 936 1. Install the seat cushion trim cover. - Install hog rings to attach the seat cushion trim cover to the seat cushion foam pad of the OCS assembly at all locations from where they were removed. 2. At the front outboard side of the seat cushion frame, attach the 2 clips. 3. On vehicles equipped with SIR seats, attach the seat cushion trim cover J-clips to the seat cushion frame. - If equipped with manual lumbar, do not attach the rear inboard J-clip at this time. 4. Install the seat cushion assembly and the 4 nuts to the seat track. - Position the safety belt buckle through the seat cushion strap. - Tighten to 25 Nm (18 lb-ft). 5. If equipped, connect the backrest heated seat element electrical connector and attach any wire harness retainers to the seat cushion frame. 6. If equipped, connect the power seat track electrical connector and attach any wire harness retainers to the seat cushion frame. 7. NOTE: If equipped with manual lumbar, make sure this wire harness is routed above the manual lumbar cable. Connect the safety belt buckle pretensioner and safety belt buckle switch electrical connectors and attach the wire harness retainer to the seat track. 8. CAUTION: To prevent component damage and avoid setting DTCs, the following precautions must be taken: - The position assurance locking wedge must be in the released position when inserting the electrical connector in the safety belt buckle and pretensioner. - Do not install the electrical connector by pushing on the position assurance locking wedge. - Make sure the electrical connector and position assurance locking wedge are fully seated after connecting to the safety belt buckle and pretensioner. Fully engage the locking wedge on the safety belt buckle and pretensioner electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Page 937 9. On vehicles with SIR seats, connect the BTS electrical connector. - Route the wire harness and connect the electrical connector. 10. If equipped, connect the manual lumbar cable. - Route the cable and attach the J-clip. 11. Install the passenger seat. Do not prove the SRS at this time. - Make sure the safety belts and buckles accessible to the occupants after installation. - Verify the safety belt retractor operates without excessive effort or binding. 12. WARNING: - Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. - Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. CAUTION: To prevent system failure, it is necessary to carry out the occupant classification sensor (OCS) system reset of the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed or an OCS system service kit is installed. A scan tool is used to trigger the command to carry out the OCS system reset. - To prevent system failure, the following precautions must be taken before carrying out the occupant classification sensor (OCS) system reset: Make sure the voltage to the occupant classification system module (OCSM) is above 8.0 volts and less than 18.0 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. NOTE: If the first attempt to carry out the OCS system reset is unsuccessful, a second attempt must be made. If the second attempt to carry out the OCS system reset is unsuccessful, a new OCS system service kit must be installed. Carry out the OCS system reset command using the scan tool. 13. Cycle the ignition switch from ON to OFF. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Page 938 14. NOTE: The ignition switch must be cycled after the OCS system reset. Cycle the ignition switch from OFF to ON. 15. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. 16. NOTE: A prepaid return postcard is provided with a new OCS service kit. The serial number for the new part and the vehicle identification number (VIN) must be recorded and sent to Ford Motor Company. When installing a new OCS service kit, fill out the necessary information on the OCS service kit traceability card and return it along with the complete inoperative OCS system to Ford Motor Company. When returning the inoperative OCS system, include the following: seat cushion foam pad, seat cushion frame, bladder, OCSM, pressure sensor (transducer), hose, electrical connectors and wire harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 942 C356 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Position Sensor - Manual Seat Track Seat Position Sensor: Service and Repair Seat Position Sensor - Manual Seat Track SEAT POSITION SENSOR - MANUAL SEAT TRACK Removal and Installation WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Depower the SRS. 2. Disconnect the seat position sensor electrical connector. 3. Remove the nut and seat position sensor. - To install, tighten to 8 Nm (71 lb-in). 4. To install, reverse the removal procedure. 5. Repower the SRS. - After installation and power is restored, position the driver seat from its forward most position to its rearmost position and then back again. While positioning the seat, make sure that the seat position sensor and bracket and the wire harness do not come in contact with any other part of the seat that may cause damage. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Position Sensor - Manual Seat Track > Page 945 Seat Position Sensor: Service and Repair Seat Position Sensor - Power Seat Track SEAT POSITION SENSOR - POWER SEAT TRACK Removal and Installation WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. NOTE: The seat position sensor is mounted at the LH rear of the seat track. Position the driver seat rearward enough so that upon removal the sensor can clear the bracket. Position the driver seat to access the seat position sensor. 2. Depower the SRS. 3. Fold the seat backrest all the way forward. 4. Disconnect the seat position sensor electrical connector. 5. Remove the nuts and seat position sensor. - To install, tighten to 8 Nm (71 lb-in). 6. To install, reverse the removal procedure. 7. Repower the SRS. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Position Sensor - Manual Seat Track > Page 946 - After installation and power is restored, position the driver seat from its forward most position to its rearmost position and then back again. While positioning the seat, make sure that the seat position sensor, bracket and wire harness do not come in contact with any other part of the seat that may cause damage. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 951 C257 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Part 1 Part 2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Page 956 Removal and Installation NOTE: - When a new lock cylinder is installed, the tailgate lock cylinder, door lock cylinders and the ignition lock cylinder should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is to be used, the new key code is attached to a tag. - The individual door lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build a new lock cylinder to the current key code of the vehicle. 1. Remove the steering wheel. 2. Remove bolt and the lower steering column shroud. 3. NOTE: The steering column shift is shown, the floor console shift is similar. Position the ignition lock cylinder cover aside. 4. Disconnect the PATS transceiver electrical connector. 5. Remove the screw and the PATS transceiver. 6. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove the lock cylinder. 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 960 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 961 C167 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 967 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 968 C1311 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 969 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example, during parking maneuvers. Power Steering Pressure (PSP) Switch Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the vehicle security module (VSM). Refer to Tire Pressure Monitoring System (TPMS) Sensor Activation. See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Programming and Relearning NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with tire pressure monitor system (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the activation tool, attempt to activate the same sensor with the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least 1/4 of a turn and attempt to activate the same sensor again. NOTE: The VSM has a 2 minute time limit between sensor responses. If the VSM does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the tire pressure must be adjusted and the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressures for front and rear tires, tire rotation will not affect the system. 1. NOTE: Click here to view an animated version of this procedure. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. ^ The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the activation tool must remain in place 180 degrees from the valve stem. Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the special tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the VSM. Click here to view an animated version of this procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 975 7. Within 2 minutes of the horn sounding, place the activation tool on the RF tire sidewall opposite (180°) from the valve stem to train the RF tire pressure sensor. 8. NOTE: Do not wait more than 2 minutes between training each sensor or the VSM will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor IDs trained to the VSM and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the VSM to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed VSM. If the sensors are being trained due to the installation of a new VSM, clear any DTCs and perform the VSM on-demand self test. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 976 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool against the LF tire sidewall 180 degrees from the tire valve stem. 3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the activation tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart. See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. 1. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. Click here to view an animated version of this procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 979 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. Click here to view an animated version of this procedure. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor may occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 980 3. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 981 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 982 Part 1 Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter, but all strap kits share the same base part number. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. Remove a factory installed strap in the following sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item on both sides of the buckle approximately 25 mm (0.98 in) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. 3. To remove a dealer-installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 4. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Click here to view an animated version of this procedure. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers may damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 983 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180 degrees from the valve stem. Click here to view a video version of this procedure. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. Click here to view an animated version of this procedure. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 in) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 984 6. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 991 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 992 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 993 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 994 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 995 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 996 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 997 Brake Switch - TCC: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 998 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 999 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1000 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1001 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1002 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1003 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 1004 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations View 151-19 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1010 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1011 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1012 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1013 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1014 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1015 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1016 Overdrive Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1017 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1018 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1019 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1020 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1021 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1022 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1023 C2135 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions Throttle Position Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1028 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1029 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1030 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1031 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1032 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1033 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1034 Throttle Position Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1035 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1036 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1037 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1038 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1039 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1040 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Mode Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1045 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1046 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1047 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1048 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1049 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1050 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1051 Transmission Mode Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1052 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1053 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1054 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1055 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1056 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1057 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 1058 Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift Transmission Control (TC) Switch - Column Shift Removal and Installation NOTE: The transmission control (TC) switch is part of the transmission range selector lever. 1. To install a new TC switch, a new transmission range selector lever must be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 1061 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Removal 1. Lift the center console lid cover and remove the console finish panel. 2. Depress the bottom of the button. Using a suitable tool, pry forward on the top of the selector lever button and remove the selector lever button. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 1062 3. Remove the screw, slide the selector lever knob up and remove the selector lever knob. 4. Remove the selector lever knob shroud. 5. Disconnect the transmission control (TC) switch electrical connector, release the selector lever bezel locking tabs and remove the selector lever bezel from the selector lever. 6. Release the 2 tabs and push the TC switch through the selector lever bezel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 1063 Installation 1. Install the TC switch in the selector lever bezel. 2. Install the selector lever bezel on the locking tabs and connect the TC switch electrical connector. 3. Install the selector lever knob shroud. 4. CAUTION: Do not overtighten the screw or damage to the selector lever knob can occur. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 1064 Install the selector lever knob and install the screw. 5. Position the selector lever button in place and press in on the top of the selector lever button to install. 6. Install the center console finish panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 Transmission Position Switch/Sensor: Locations View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 1068 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 1071 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 1072 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 1073 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 1074 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 1075 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 1076 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 1077 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 1078 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 1079 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 1080 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 1081 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 1082 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 1083 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 1084 C167 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 1085 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the selector lever cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 4. Loosen the digital transmission range (TR) sensor bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 1086 5. NOTE: The manual control lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 lb-in). 7. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever shaft outer nut. ^ Tighten to 33 Nm (24 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 1087 8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. With the manual control lever in overdrive connect the selector lever cable. 9. Lower the vehicle. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 1088 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Removal NOTE: The manual control lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the selector lever cable. Disconnect the selector lever cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 1089 3. Disconnect the digital transmission range (TR) electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 1090 Installation 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 1091 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 lb-ft). 5. Connect the digital TR sensor electrical connector. 6. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable end to the manual control lever with the lever in the (D) position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 1092 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Locations Output Shaft Speed (OSS) Sensor View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 1097 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 1098 View 151-12 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 1099 Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 1100 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1103 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1104 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1105 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1106 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1107 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1108 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1109 Transmission Speed Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1110 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1111 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1112 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1113 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1114 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1115 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1116 Transmission Speed Sensor: Connector Views C193 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1117 C1107 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1118 C143 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 3. Remove the TSS sensor bolt and sensor. ^ Remove the TSS sensor bolt. ^ Remove the TSS sensor. 4. To install, reverse the removal procedure. ^ Tighten bolt to 11 Nm (8 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 1121 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the output shaft speed (OSS) sensor electrical connector. 3. Remove the OSS sensor bolt and sensor. ^ Remove the OSS sensor bolt. ^ Remove the OSS sensor. 4. To install, reverse the removal procedure. ^ Tighten bolt to 12 Nm (9 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1126 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1127 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1128 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1129 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1130 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1131 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1132 Transmission Temperature Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1133 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1134 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1135 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1136 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1137 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 1138 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Power Sliding Window Switch, Rear View 151-35 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Power Sliding Window Switch, Rear > Page 1144 Power Window Switch: Locations Window Adjust Switch, Left/Right Rear View 151-32 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Power Sliding Window Switch, Rear > Page 1145 View 151-33 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Power Sliding Window Switch, Rear > Page 1146 View 151-30 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Power Sliding Window Switch, Rear > Page 1147 View 151-31 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch Power Window Switch: Diagrams Master Window Adjust Switch C504A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1150 C504B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1151 C535 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1152 C701 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1153 C604 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1154 C801 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1155 C980 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch Power Window Switch: Testing and Inspection Master Window Adjust Switch Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 1158 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 1159 Power Window Switch: Testing and Inspection Master Window Adjust Switch (Regular Cab) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 1160 Power Window Switch: Testing and Inspection Power Sliding Window Switch, Rear Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 1161 Power Window Switch: Testing and Inspection Power Window Switches, Rear Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 1162 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 1163 Power Window Switch: Testing and Inspection Window Adjust Switch, Passenger Side Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 1164 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Window Control Switch - Front Power Window Switch: Service and Repair Window Control Switch - Front WINDOW CONTROL SWITCH - FRONT Removal and Installation 1. Remove the window control switch bezel. 2. Disconnect the window control switch electrical connectors. 3. Remove the window control switch. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Window Control Switch - Front > Page 1167 Power Window Switch: Service and Repair Window Control Switch - Rear WINDOW CONTROL SWITCH - REAR Removal and Installation 1. Remove the window control switch bezel. 2. Disconnect the window control switch electrical connectors. 3. Remove the window control switch. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations View 151-19 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1172 Windshield Washer Switch: Diagrams C202A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1173 C202B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1174 C202C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1175 Windshield Washer Switch: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1176 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations View 151-19 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1180 Wiper Switch: Diagrams C202A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1181 C202B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1182 C202C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1183 Wiper Switch: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1184 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications Alignment: Specifications Alignment Specifications Alignment Specifications Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1190 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1191 Alignment: Specifications General Specifications General Specifications Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1192 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1193 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1194 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1195 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1196 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1197 Alignment: Specifications Torque Specifications Torque Specifications Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1198 Alignment: Description and Operation Wheel Alignment Angles Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications in this section will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Toe Positive Toe (Toe In) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1199 Negative Toe (Toe Out) The vehicle toe setting affects tire wear and directional stability. Incorrect Thrust Angle (Dogtracking) Incorrect thrust angle (dogtracking) is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Wander Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down a level road. Shimmy Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1200 Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph) and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface. Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and observed by the driver as small rotational oscillations of the steering wheel. For wheel and tire diagnosis, refer to Section 204-04. Poor Returnability/Sticky Steering Poor returnability and sticky steering is used to described the poor return of the steering wheel to center after a turn or the steering correction is completed. Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (for example: wind, road crown). Poor Groove Feel Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20 degrees of steering wheel turn). Efforts may be said to be "flat on center." ^ Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. ^ In the diagnosis of a roadability problem, it is important to understand the difference between wander and poor groove feel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Alignment: Service and Repair Camber and Caster Adjustment Camber and Caster Adjustment 1. Using alignment equipment and the manufacturer's instruction, measure the caster and camber. 2. NOTE: New lower arm-to-frame mounting bolts must be installed with cam bolt kits to allow for adjustment of the arm in the frame slot. NOTE: The rear lower control arm-to-frame bolt must be reversed in order to install the alignment kit to allow access for a torque wrench. Remove the nuts and bolts from the LH and RH lower control arms at the frame attachments. ^ Discard the nuts and bolts. ^ Loosen the LH and RH stabilizer bar-to-frame bracket nuts. Support the stabilizer bar. ^ Install the cam bolt kit(s) and snug the nut(s). 3. To adjust the caster and camber, refer to the chart. ^ Adjustments that require moving the front and the rear of the lower arm should be made equally. 4. While holding the cam bolt, tighten the nut(s). 5. Recheck the caster and camber settings and adjust as necessary. 6. Check and, if necessary, adjust the front toe. 7. Tighten the LH and RH stabilizer bar bracket nuts to 48 Nm (35 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1203 8. Set the final torque to 300 Nm (222 lb-ft) on the nuts only. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1204 Alignment: Service and Repair Ride Height Measurement Ride Height Measurement Front Ride Height Measurement NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure. Vehicle should have at least 1/2 tank of fuel. 1. Position a suitable surface gauge (such as Starrett 57D Surface Gauge) on a flat, level surface and adjust the gauge's arm until the scriber point is located in the center of the rearward lower arm bolt. ^ Lock the surface gauge in this position. 2. With the surface gauge positioned on a flat, level surface, record the measurement of the surface gauge position (measurement A). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1205 3. Position the surface gauge on the same flat, level surface as used in Step 1 and adjust the gauge's arm until the scriber point is located at the lowest point on the wheel knuckle. ^ Lock the surface gauge in this position. 4. With the surface gauge positioned on a flat, level surface, record the measurement of the surface gauge position (measurement B). 5. Subtract measurement B from measurement A to obtain the front ride height. ^ Refer to Specifications. Rear Ride Height Measurement, Rear Wheel Drive (RWD) vehicles Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1206 NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure. Vehicle should have at lease 1/2 tank of fuel. 1. Measure the distance between the rear axle jounce stop (Item 2) and the top of the rear axle tube (Item 3) to obtain the rear ride height (Item 1). Rear Ride Height Measurement, Four Wheel Drive (4WD) vehicles NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure. Vehicle should have at lease 1/2 tank of fuel. 1. Measure the distance between the rear axle jounce stop (Item 2) and the top of the rear spring spacer (Item 3) to obtain the rear ride height (Item 1). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1207 Alignment: Service and Repair Toe Adjustment - Front Toe Adjustment - Front 1. Using alignment equipment and the manufacturer's instructions, measure the toe. 2. Start the engine and center the steering wheel. 3. Turn the engine OFF, and hold the steering wheel in the straight-ahead position using a suitable holding device. 4. NOTE: Do not allow the steering gear bellows to twist when the front wheel spindle tie rod is rotated. Remove the outer bellows clamps. 5. Loosen the tie-rod jam nuts. 6. Rotate the inner tie rods. 7. CAUTION: Make sure to hold the tie-rod end stationary with a wrench while tightening the nut or damage to the boot can occur. NOTE: Make sure that the toe settings are not disturbed while tightening the jam nuts. Tighten the tie-rod jam nuts to 70 Nm (52 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1208 8. Install the clamps. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Item....................................................................................................................................................... ..............................................................Specification Fuel Pressure Engine running..................................................................................................................................... ..............................................193-310 kPa (28-45 psi) Key ON, engine OFF (KOEO)......................... ..................................................................................................................................240-310 kPa (35-45 psi) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1213 Fuel Pressure: Testing and Inspection FUEL SYSTEM PRESSURE TEST Special Tool(s) Special Tool(s) WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. 1. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. 2. NOTE: 5.4L shown, 4.6L and 4.2L similar. Install the special tools in line between the fuel supply tube and fuel rail. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1214 3. NOTE: The electrical connector was disconnected during fuel system pressure release. Connect the electrical connector. 4. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 5. Test the fuel system pressure to make sure it is within the specified range. 6. NOTE: - 5.4L shown, 4.6L and 4.2L similar. - Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Upon completion of the fuel system pressure test, open the drain valve on the special tool and relieve the fuel system pressure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Typical Diagnostic Reference Value Measured/PID Values 665 RPM .......................................................................................................... ..................................................................................................... Hot Idle Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair AIR CLEANER ELEMENT Exploded View Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. Detach the electrical connector retainer. 2. Loosen the clamp and disconnect the air cleaner outlet pipe from the air cleaner cover. - To install, tighten to 4 Nm (35 lb-in). 3. Open the clamp and detach the air cleaner cover from the air cleaner tray. 4. Remove the air cleaner element. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE Special Tool(s) Special Tool(s) 1. NOTE: The splash shield is located on the LH frame rail under the driver side door. Disconnect the splash shield and position aside. 2. Disconnect the electrical connector. 3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition switch to the OFF position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 1226 6. When fuel system service is complete, connect the electrical connector. 7. Reposition the splash shield and install a new pushpin. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Install the scan tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON. Select the appropriate vehicle and engine qualifier. Clear all DTCs and carry out a PCM reset. 10. Start the vehicle and check the fuel system for leaks. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing order........................................................................................................................................... ...........................................................1-3-7-2-6-5-4-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications Item....................................................................................................................................................... ..............................................................Specification Base timing........................................................................................................................................... ............................10° before top dead center (BTDC) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions TSB 08-7-6 04/14/08 SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008 Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part List. ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and 2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07. ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and extract broken spark plugs. SERVICE PROCEDURE The engine build date can be read on the left hand cam cover information sticker. To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before removal is attempted. CAUTION DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS COULD BE DAMAGED. Spark Plug Removal Procedure 1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and surrounding valve cover area with compressed air. 2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4 teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark plug back and forth at this point. NOTE COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL. CAUTION EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE. CAUTION DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST ONLY BE REMOVED WITH HAND TOOLS. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1237 3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the back and forth turning as needed until turning effort is reduced, and remove the spark plugs. NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. (Figure 1) Separated/Broken Spark Plug Removal If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of three modes. Refer to the appropriate removal procedure as required. a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2) b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head. (Figure 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1238 c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground shield. (Figure 4) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1239 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1240 Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the cylinder head. (Figure 6) NOTE THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD. IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL. 1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be removed. (Figure 7) 2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and protect the combustion chamber from contamination. (Figure 7) 3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4 reduced diameter threads on the tip end). a. Coat the end of the tap with general purpose grease. (Figure 8) b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K) is provided with service tool 303-1203 update to connect the tap to a 3/8" socket Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1241 drive. CAUTION DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED. 4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9) a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out. b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to prevent thread stripping. c. Install the nylon washer and jack nut until finger tight. d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool assembly. NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. Mode 2 Procedure: 1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug well and allow 15 minutes of soak time. 2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking care not to fracture the porcelain. 3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder head. Mode 3 Procedure: CAUTION DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1242 Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground electrode shield. (FIGURE 10) Porcelain Removal - Preparation CAUTION THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21 °C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF ADHESIVE. CAUTION DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR BONDING. 1. Remove any remaining electrode material from broken porcelain with long nose reach pliers. 2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the straw nozzle supplied with the brake cleaner can. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1243 3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1244 4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14) NOTE PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN. 5. Insert the completed assembly into the spark plug well and fully engage the pin into the porcelain. (Figure 15) 6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to flood the porcelain and pin. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1245 7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take care making sure the pin does not disengage the porcelain. (Figure 16). 8. Repeat Steps 6 and 7. 9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry compressed air. NOTE CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN. 10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed. 11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry compressed air. Porcelain Removal - Bonding Process CAUTION USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER HEAD. NOTE WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES. 1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator. (Figure 17) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1246 2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18). 3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2. 4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent starts to cure. 5. Reassemble a dry and clean collet and pin assembly. 6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of Loctite® 638TMare being used if it drips off the pin. 7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin. 8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain with a twisting motion to spread the bonding agent. 9. Add additional Loctite® 638TM, repeating Steps 6-8. 10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19). CAUTION A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE EXTRACTION IS ATTEMPTED. 11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C). 12. Repeat the bonding process for remaining cylinders as needed. Porcelain Removal - Extraction 1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded rod. 2. Install the washer and jack nut until finger tight against the tool pilot bushing. CAUTION ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL. 3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is free of the ground electrode. 4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder head. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1247 NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7) Porcelain Removal - Pin Slipped Out In the unlikely event that the pin does not remove the broken porcelain, this process can be repeated. Key elements to success are: ^ Clean and dry porcelain ^ Sufficient Loctite® 638TM Retaining Compound spread uniformly ^ Loctite(R) 638(TM) cure time and temperature ^ Preventing the threaded rod from rotating while removing the porcelain Replacement Supplies Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT080706 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 12405 01 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > General Specifications Spark Plug: Specifications General Specifications Item....................................................................................................................................................... ..............................................................Specification Spark plug gap..................................................................................................................................... ....................................1.32-1.42 mm (0.052-0.056 in) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > General Specifications > Page 1250 Torque Specifications Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1251 Spark Plug: Application and ID Item....................................................................................................................................................... ..............................................................Specification Spark plug............................................................................................................................................ ...................................................................AGSF-32N Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1252 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Install a new spark plug. 2. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. ^ Install new spark plugs. 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1253 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a Heli-Coil(R) insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by white or light gray spots and with a bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Install new spark plugs. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1254 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1255 Spark Plug: Service and Repair SPARK PLUGS Exploded View Removal and Installation 1. Remove the ignition coil-on-plug. 2. CAUTION: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. - If an original spark plug is used, make sure it is installed in the same cylinder from which it was taken. New spark plugs can be used in any cylinder. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1256 Remove the spark plugs. To install, tighten to 15 Nm (11 lb-ft). 3. Inspect the spark plugs. Install new spark plugs as necessary. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1260 Compression Check: Testing and Inspection Compression Test - Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of 5 compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1261 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75% of the highest reading. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance This engine is equipped with hydraulic lash adjusters. No adjustment is required. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start Drive Belt: Customer Interest Engine - FEAD Idler Pulley Noise During Cold Start TSB 09-9-7 05/18/09 COLD START FEAD HOOT - WHISTLE NOISE FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150 LINCOLN: 2007-2008 Mark LT, Navigator MERCURY: 2007-2008 Mountaineer This article supersedes TSB 8-4-2 to remove the production build date. ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine; 2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer, Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive (FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED. 1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, Section 303-05. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 090907A 2007-2008 F-150/Mark LT 0.3 Hr. 4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Explorer/Mountaineer/ Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 1273 Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 Mustang 4.6L: 0.3 Hr. Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) DEALER CODING CONDITION BASIC PART NO. CODE 6C348 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start Drive Belt: All Technical Service Bulletins Engine - FEAD Idler Pulley Noise During Cold Start TSB 09-9-7 05/18/09 COLD START FEAD HOOT - WHISTLE NOISE FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150 LINCOLN: 2007-2008 Mark LT, Navigator MERCURY: 2007-2008 Mountaineer This article supersedes TSB 8-4-2 to remove the production build date. ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine; 2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer, Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive (FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED. 1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, Section 303-05. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 090907A 2007-2008 F-150/Mark LT 0.3 Hr. 4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Explorer/Mountaineer/ Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 1279 Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 Mustang 4.6L: 0.3 Hr. Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) DEALER CODING CONDITION BASIC PART NO. CODE 6C348 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 08-4-4 > Mar > 08 > Engine Controls - Cold Start Hesitation/Intake Backfire PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Cold Start Hesitation/Intake Backfire TSB 08-4-4 03/03/08 COLD START ROUGH RUNNING/HESITATION/BACKFIRE - 4.6 ONLY FORD: 2007-2008 F-150 ISSUE Some 2007-2008 F-150 vehicles equipped with a 4.6L engine, may exhibit a rough running, hesitation and/or induction backfire during the first drive away event following an overnight or extended soak. No diagnostic trouble codes (DTCs) or other driveability concerns should be observed. This typically occurs when the ambient temperature is below 60 °F (16 °C). The event will last only 20-40 seconds and normal operation will return once the system enters closed loop. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF OTHER DRIVEABILITY CONCERNS ARE PRESENT OR NOTED BY THE CUSTOMER, DO NOT CONTINUE WITH THIS TSB. FOLLOW NORMAL WORKSHOP MANUAL (WSM) DIAGNOSTICS. NOTE NO DTC'S WILL BE PRESENT WITH THE CONDITION THIS CALIBRATION IS DESIGNED TO ADDRESS. IF DTC'S ARE PRESENT DO NOT CONTINUE WITH THIS TSB. FOLLOW NORMAL WSM DIAGNOSTICS. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 53.4 and higher. This new calibration is not included in the VCM 2008.1 DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 080404A 2007-2008 F-150 4.6: 0.3 Hr. Check DTCs Reprogram The PCM Authorization Decal Not Required (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1290 Drive Belt: Locations Accessory Drive 4.2 With A/C 4.2L Without A/C 4.6L (2V) And 5.4L (3V) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1291 Drive Belt: Diagrams Accessory Drive 4.2 With A/C 4.2L Without A/C 4.6L (2V) And 5.4L (3V) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1292 Drive Belt: Description and Operation Accessory Drive 4.2 With A/C 4.2L Without A/C 4.6L (2V) And 5.4L (3V) The accessory drive system: - has a single serpentine drive belt (6 ribs). - has 2 idler pulleys - 4.2L. - has 3 idler pulleys - 4.6L (2V) and 5.4L (3V). - has an automatic belt tensioner. - is not adjustable. The accessory drive system provides power to operate components which power other systems. These could include components such as the generator, power steering pump, and A/C compressor. Each of these components is equipped with a pulley which is driven by the accessory drive belt. The accessory drive belt is driven by the engine crankshaft pulley. One or more idler pulleys may be provided to facilitate belt routing and alignment. The Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1293 automatic belt tensioner maintains correct belt tension and compensates for component wear and changes in system load. System load changes can be caused by the A/C compressor clutch engaging and disengaging, or demand changes on other systems powered by the accessory drive belt. To maintain correct operation of this stem, it is critical that the correct length drive belt be installed. The pulleys must also be correctly aligned and kept clean. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview Inspection and Verification CAUTION: Under no circumstances should the accessory drive belt, tensioner or pulleys have any fluids or belt dressing applied to them as damage to the belt material and tensioner damping mechanism may occur. 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical damage. Visual Inspection Chart Visual Inspection Chart Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1296 Belt Tensioner With Belt Length Indicator 3. Check that the belt length indicator, if equipped, on the belt tensioner is in the acceptable belt installation and wear range. If the indicator is in the belt replacement range, either an incorrect belt is installed or the belt is worn beyond the service limit. Install a new belt as necessary. 4. Eliminate all other non-belt related noises that could cause belt misdiagnosis, such as A/C compressor engagement chirp, A/C slugging noise, power steering cavitations at low temperatures, variable camshaft timing (VCT) tick or generator whine. 5. If a concern is found, correct the condition before proceeding to the next step. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1297 V-Ribbed Serpentine Drive Belt With Cracks Across Ribs 6. Check the belt for cracks. Up to 15 cracks in a rib over a distance of 100 mm (4.0 inch) can be considered acceptable. If cracks exceed this standard, install a new belt. NOTE: Piling is an excessive buildup in the V-grooves of the belt. V-Ribbed Serpentine Belt With Piling 7. The condition of the V-ribbed drive belt should be compared against the illustration and appropriate action taken. 1 Small scattered deposits of rubber material. This is not a concern, therefore, installation of a new belt is not required. 2 Longer deposit areas building up to 50% of the rib height. This is not considered a durability concern, but it can result in excessive noise. If noise is apparent, install a new belt. 3 Heavy deposits building up along the grooves resulting in a possible noise and belt stability concern. If heavy deposits are apparent, install a new belt. V-Ribbed Serpentine Belt With Chunks of Rib Missing Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1298 8. There should be no chunks missing from the belt ribs. If the belt shows any evidence of this, install a new accessory drive belt. 9. If the concern is not visually evident, verify the symptom and GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1299 Drive Belt: Symptom Related Diagnostic Procedures Symptom Chart Symptom Chart (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1300 Symptom Chart (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1301 Drive Belt: Component Tests and General Diagnostics Component Tests Drive Belt - Noise/Flutter CAUTION: Under no circumstances should the accessory drive belt, tensioner or pulleys have any fluids or belt dressing applied to them as damage to the belt material and tensioner damping mechanism may occur. Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged or incorrectly aligned grooved pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley. Look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. Drive belt squeal may be an intermittent or constant noise that occurs when the drive belt slips on an accessory pulley under certain conditions. A short intermittent squeal may occur during engine start-up and shut down or during very rapid engine acceleration and decelerations, such as: ^ wide open throttle (WOT) 1-2 and 2-3 shifts or 2-3 and 3-4 back out shifts on automatic transmissions. ^ WOT 1-2 and 2-3 shifts and any combination of rapid downshifting on manual transmissions. These special short-term transient events are expected, and are due to the higher system inertias required to meet the electrical and cooling demands on today's vehicle systems. Constant or reoccurring drive belt squeal can occur: ^ if the A/C discharge pressure goes above specifications: - the A/C system is overcharged. - the A/C condenser core airflow is blocked. ^ if the A/C off equalized pressure (the common discharged and suction pressure that occurs after several minutes) exceeds specifications. ^ if any of the accessories or idler pulley(s) are damaged or have a worn or damaged bearing. All accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. ^ if there is evidence of fluid contamination on the accessory drive belt. When the drive belt has been exposed to fluid contamination during vehicle operation, such as leaks from the power steering system, A/C system or cooling system, clean all pulleys with soap and water, rinse with clean water and install a new accessory drive belt. If the drive belt has been exposed to fluids in a localized area during routine vehicle service, such as replacement of hoses or fluids, the drive belt and pulleys should be washed with soap and water immediately (prior to starting the engine), and rinsed with clean water. ^ if the accessory drive belt is too long. A drive belt that is too long will allow the accessory drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the accessory drive belt tensioner indicator is outside the normal installation wear range window, install a new accessory drive belt. NOTE: The accessory drive belt tensioner arm should rotate freely without binding. Install a new accessory drive belt tensioner if the drive belt tensioner is worn or damaged. Drive Belt - Incorrect Installation CAUTION: Incorrect accessory drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the pulleys. Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt tracks incorrectly, install a new accessory drive belt to avoid performance failure or loss of the drive belt. Incorrect Installation Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1302 Correct Installation With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the accessory drive belt rides beyond the edge of the pulleys, noise and premature wear will occur. Make sure the accessory drive belt rides correctly on the pulley. If an accessory drive belt tracking condition exists, proceed with the following: ^ Visually check the accessory drive belt tensioner for damage and wear, especially the mounting pad surface and arm alignment. If the accessory drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. If the tensioner arm is worn, the arm will be out of alignment. Either of these conditions will result in chirp and squeal noises. ^ With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the pulley forward faces) for excessive wobble. Install new components as necessary. ^ Check all accessories, mounting brackets and the accessory drive belt tensioner for any interference that would prevent the component from mounting correctly. Correct any interference condition and recheck the accessory drive belt tracking. ^ Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware to specification. Recheck the accessory drive belt tracking. Belt Tensioner - Mechanical The only mechanical check that needs to be made is a check for tensioner stick, grab or bind. 1. With the engine off, check routing of the accessory drive belt. Refer to the illustrations under Description and Operation in this section. 2. NOTE: The accessory drive belt tensioner spring is very strong and requires substantial force to release. Using a suitable, commercially available serpentine belt tensioner release tool, release the tension on the belt and detach the accessory drive belt from the tensioner. Carry out the following tests: ^ Using the release tool, move the tensioner from its relaxed position, through its full stroke and back to the relaxed position to make sure there is no stick, grab or bind, and to make sure that there is tension on the tensioner spring. ^ Rotate the tensioner pulley by hand and check for a binding, contaminated or seized condition. ^ Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination and repair any leaks. 3. If the accessory drive belt tensioner does not meet the criteria in the previous step, install a new tensioner. If the accessory drive belt tensioner meets the criteria in the previous step, proceed to testing the tensioner dynamically. Belt Tensioner - Dynamics The accessory drive belt tensioner can be checked dynamically as follows: 1. With the engine running, observe the accessory drive belt tensioner movement. The accessory drive tensioner should move (respond) when the A/C clutch cycles (if equipped), or when the engine is accelerated rapidly. If the accessory drive belt tensioner movement is excessive without A/C clutch cycling or engine acceleration, check belt rideout. Excessive belt rideout (uneven depth of grooves in the belt) can cause excessive accessory drive belt tensioner movement. Check rideout condition by installing a new belt. If excessive accessory drive belt tensioner movement still exists, install a new accessory drive belt tensioner. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1303 Drive Belt: Service and Repair Accessory Drive Removal 1. Rotate the drive belt tensioner clockwise and remove the drive belt. Installation 1. To install, reverse the removal procedure. 4.2 With A/C 4.2L Without A/C 4.6L (2V) And 5.4L (3V) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair AIR CLEANER ELEMENT Exploded View Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. Detach the electrical connector retainer. 2. Loosen the clamp and disconnect the air cleaner outlet pipe from the air cleaner cover. - To install, tighten to 4 Nm (35 lb-in). 3. Open the clamp and detach the air cleaner cover from the air cleaner tray. 4. Remove the air cleaner element. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair This vehicle is not equipped with a cabin air filter. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair Evaporative Canister Filter: Service and Repair DUST SEPARATOR Evaporative Emission (EVAP) Canister Purge Valve Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair > Page 1315 EVAP Canister Assembly - Removal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair > Page 1316 EVAP Canister Assembly - Disassembly Exploded View Removal and Installation WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. NOTE: The evaporative emission (EVAP) canister assembly is located above the spare tire. Remove the spare tire. 4. Disconnect the fuel vapor tube quick connect coupling. 5. Disconnect the fuel vapor hose. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair > Page 1317 6. Remove the 2 front EVAP canister assembly bracket bolts. - To install, tighten to 13 Nm (10 lb-ft). 7. Remove the 2 outer rear EVAP canister assembly bracket bolts. - To install, tighten to 20 Nm (15 lb-ft). 8. Remove the 2 inner rear EVAP canister assembly bracket bolts. - To install, tighten to 13 Nm (10 lb-ft). 9. Lower the EVAP canister assembly down slightly to disconnect the EVAP canister vent solenoid electrical connector and remove the EVAP canister vent solenoid harness pushpin retainer. 10. Remove the EVAP canister assembly. 11. Disconnect the EVAP canister vent solenoid-to-dust separator fuel vapor hose. 12. Release the clips and remove the dust separator from the EVAP canister assembly. 13. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter Fluid Filter - A/T: Service and Repair Fluid Pan, Gasket and Filter Fluid Pan, Gasket and Filter Removal CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail; this will effect the operation of the transmission. Use of a transmission fluid other than specified could result in transmission failure. NOTE: Normal maintenance requires periodic automatic transmission fluid changes. If a major repair, such as a clutch, band or bearing, is required, the automatic transmission will need to be removed for repair. The transmission fluid needs to be changed if evidence of transmission fluid contamination is found. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid. ^ Loosen the transmission fluid pan bolts and allow transmission fluid to drain. After transmission fluid is drained remove the bolts. 3. Remove the transmission fluid pan and transmission fluid pan gasket. 4. Pull down evenly and remove the transmission fluid filter and seal. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 1322 5. Clean and inspect the transmission fluid pan, gasket and magnet. Installation 1. CAUTION: If installing a new transmission fluid filter and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. NOTE: If transmission is being repaired for a contamination-related failure, use a new transmission fluid filter and seal. The transmission fluid filter may be reused if no excessive contamination is present. Install a new transmission fluid filter and seal as required. 2. Position the pan magnet into the transmission fluid pan. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 1323 3. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage; if not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and gasket. 1 Position the transmission fluid pan and gasket. 2 Install the transmission fluid pan bolts. ^ Tighten to 14 Nm (10 lb-ft). 4. NOTE: When filling a dry transmission and converter, start with a minimum of 4.7L (5 qt). Fill the transmission to the correct level with clean transmission fluid. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 1324 Fluid Filter - A/T: Service and Repair Transmission Filter - In Line Transmission Filter - In Line Transmission fluid in-line filter - with an oil-to-air (OTA) cooler NOTE: Use the following guidelines for installing the transmission fluid in-line filter: ^ If the transmission was overhauled and the vehicle was equipped with a transmission fluid in-line filter, install a new transmission fluid in-line filter. ^ If the transmission was overhauled and the vehicle was not equipped with a transmission fluid in-line filter, install a new transmission fluid in-line filter kit. ^ If the transmission is being installed for a non-internal repair, do not install a transmission fluid in-line filter or filter kit. ^ If installing a new or a Ford-authorized remanufactured transmission, install a transmission fluid in-line filter. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the bolts and the skid plate. 3. Remove the section of the rubber hose and steel tube as illustrated. ^ Clean and de-burr the end of the steel tube. 4. NOTE: Be sure the transmission fluid cooler tube is fully seated in the body of the fitting before final tightening of the ferrule nut. Install the tubing ferrule hose assembly connector onto the end of the steel transmission fluid cooler tube. Finger-tighten the ferrule nut, then tighten the nut an additional 1-1/2 turns to seat the ferrule in the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 1325 5. CAUTION: The transmission fluid in-line filter has a bypass valve in it. The arrow on the transmission fluid in-line filter indicates the direction of transmission fluid flow through the transmission fluid in-line filter. The transmission fluid in-line filter must be installed in the transmission fluid cooler return tube with the arrow on the transmission fluid in-line filter pointing away from the transmission fluid cooler and toward the transmission (the return tube has transmission fluid coming out of the cooler going to the transmission). If the transmission fluid in-line filter is not installed correctly, it will cause internal transmission damage. CAUTION: Do not install any rubber hoses or steel tubing with a bend entering the filter greater than 60 degrees. Using a suitable length of hose install the transmission fluid in-line filter. Tighten the hose clamps. 6. Clean a section of the transmission fluid pan and install the sticker. 7. If equipped, install the skid plate and the bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 1326 8. Fill the transmission with clean transmission fluid. ^ Verify for correct operation. ^ Check the filter for leaks. Transmission fluid in-line filter - without an OTA cooler NOTE: Use the following guidelines for installing the transmission fluid in-line filter: ^ If the transmission was overhauled and the vehicle was equipped with a transmission fluid in-line filter, install a new transmission fluid in-line filter. ^ If the transmission was overhauled and the vehicle was not equipped with a transmission fluid in-line filter, install a new transmission fluid in-line filter kit. ^ If the transmission is being installed for a non-internal repair, do not install a transmission fluid in-line or filter kit. ^ If installing a new or a Ford-authorized remanufactured transmission, install a transmission fluid in-line filter. 9. With the vehicle in NEUTRAL, position it on a hoist. 10. Remove the cooler tubes retainers. 11. Remove the section of the steel tube as illustrated. ^ Clean and de-burr the end of the steel tubes. 12. NOTE: Be sure the cooler tube is fully seated in the body of the fitting before final tightening of the ferrule nut. Install the tubing ferrule hose assembly connector onto the end of the steel fluid cooler tubes. Finger-tighten the ferrule nut, then tighten the nut an Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 1327 additional 1-1/2 turns to seat the ferrule in the connector. 13. CAUTION: The transmission fluid in-line filter has a bypass valve in it. The arrow on the transmission fluid in-line filter indicates the direction of transmission fluid flow through the transmission fluid in-line filter. The transmission fluid in-line filter must be installed in the transmission fluid cooler return tube with the arrow on the transmission fluid in-line filter pointing away from the transmission fluid cooler and toward the transmission (the return tube has transmission fluid coming out of the cooler going to the transmission). If the transmission fluid in-line filter is not installed correctly, it will cause internal transmission damage. CAUTION: Do not install any rubber hoses or steel tubing with a bend entering the filter greater than 60 degrees. Using a suitable length of hose install the transmission fluid in-line filter. Tighten the hose clamps. 14. Install one cooler tube retainer as illustrated. 15. Secure the cooler tubes together with a tie strap. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 1328 16. Clean a section of the transmission fluid pan and install the sticker. 17. Fill the transmission with clean transmission fluid. ^ Verify for correct operation. ^ Check the filter for leaks. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE Special Tool(s) Special Tool(s) 1. NOTE: The splash shield is located on the LH frame rail under the driver side door. Disconnect the splash shield and position aside. 2. Disconnect the electrical connector. 3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition switch to the OFF position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 1333 6. When fuel system service is complete, connect the electrical connector. 7. Reposition the splash shield and install a new pushpin. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Install the scan tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON. Select the appropriate vehicle and engine qualifier. Clear all DTCs and carry out a PCM reset. 10. Start the vehicle and check the fuel system for leaks. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures Heater Hose: Customer Interest A/C - Compressor Shuts OFF in High Temperatures TSB 07-24-7 12/10/07 A/C COMPRESSOR SHUTOFF - HIGH AMBIENT TEMPERATURES - VEHICLE STATIONARY IN GEAR FORD: 2007-2008 F-150, F-150 LINCOLN: 2007-2008 Mark LT ISSUE Some 2007-2008 Mark LT and F-150 vehicles equipped with 5.4L or 4.6L engine only, may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C), when the vehicle is stationary for periods longer than 15 minutes, with the transmission in gear. Idling in gear and extreme ambient temperatures may cause the vehicle control systems to disable A/C compressor operation. ACTION Follow the Service Procedure steps to replace the A/C compressor pulley and coolant pump pulley. SERVICE PROCEDURE NOTE THIS TSB IS INTENDED TO RESTORE A/C COMPRESSOR OPERATION IN EXTREME HIGH AMBIENT TEMPERATURES WHEN THE TRANSMISSION IS PLACED IN THE PARK POSITION. DO NOT ATTEMPT TO ADDRESS CUSTOMER CONCERNS OF GENERAL A/C TEMPERATURE OUTPUT PERFORMANCE WITH THIS TSB. THIS TSB WILL NOT IMPROVE A/C SYSTEM DUCT TEMPERATURE OUTPUT PERFORMANCE. NOTE DURING EXTREME HIGH AMBIENT TEMPERATURES WHEN IDLING STATIONARY FOR EXTENDED PERIODS OF TIME IN GEAR, IT IS RECOMMENDED TO OPERATE THE A/C IN THE MAX POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, AND PUT THE TRANSMISSION INTO THE PARK POSITION TO CONTINUE TO RECEIVE COOL AIR FROM THE A/C SYSTEM. 1. Replace the A/C compressor pulley. Follow Workshop Manual (WSM), Section 412-01 for removal and installation details. 2. Replace the coolant pump pulley. Follow WSM, Section 303-03 for removal and installation details. 3. Drain approximately 1 quart of coolant from the cooling system into a clean container which will permit reuse of coolant in the vehicle. Refer to WSM, Section 303-03. 4. Replace the clamp on the heater core feed hose, near the right hand front of engine, at the water pump outlet pipe connection point. 5. Refill the cooling system. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072407A 2007-2008 F-150 4X2, 1.7 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X2. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures > Page 1343 8509A,8620F, 8616A, 18472A). 072407B 2007-2008 F-150 4X4, 1.9 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X4. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, 8509A,8620F, 8616A, 18472A). DEALER CODING CONDITION BASIC PART NO. CODE 8A616 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures Heater Hose: All Technical Service Bulletins A/C - Compressor Shuts OFF in High Temperatures TSB 07-24-7 12/10/07 A/C COMPRESSOR SHUTOFF - HIGH AMBIENT TEMPERATURES - VEHICLE STATIONARY IN GEAR FORD: 2007-2008 F-150, F-150 LINCOLN: 2007-2008 Mark LT ISSUE Some 2007-2008 Mark LT and F-150 vehicles equipped with 5.4L or 4.6L engine only, may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C), when the vehicle is stationary for periods longer than 15 minutes, with the transmission in gear. Idling in gear and extreme ambient temperatures may cause the vehicle control systems to disable A/C compressor operation. ACTION Follow the Service Procedure steps to replace the A/C compressor pulley and coolant pump pulley. SERVICE PROCEDURE NOTE THIS TSB IS INTENDED TO RESTORE A/C COMPRESSOR OPERATION IN EXTREME HIGH AMBIENT TEMPERATURES WHEN THE TRANSMISSION IS PLACED IN THE PARK POSITION. DO NOT ATTEMPT TO ADDRESS CUSTOMER CONCERNS OF GENERAL A/C TEMPERATURE OUTPUT PERFORMANCE WITH THIS TSB. THIS TSB WILL NOT IMPROVE A/C SYSTEM DUCT TEMPERATURE OUTPUT PERFORMANCE. NOTE DURING EXTREME HIGH AMBIENT TEMPERATURES WHEN IDLING STATIONARY FOR EXTENDED PERIODS OF TIME IN GEAR, IT IS RECOMMENDED TO OPERATE THE A/C IN THE MAX POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, AND PUT THE TRANSMISSION INTO THE PARK POSITION TO CONTINUE TO RECEIVE COOL AIR FROM THE A/C SYSTEM. 1. Replace the A/C compressor pulley. Follow Workshop Manual (WSM), Section 412-01 for removal and installation details. 2. Replace the coolant pump pulley. Follow WSM, Section 303-03 for removal and installation details. 3. Drain approximately 1 quart of coolant from the cooling system into a clean container which will permit reuse of coolant in the vehicle. Refer to WSM, Section 303-03. 4. Replace the clamp on the heater core feed hose, near the right hand front of engine, at the water pump outlet pipe connection point. 5. Refill the cooling system. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072407A 2007-2008 F-150 4X2, 1.7 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X2. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures > Page 1349 8509A,8620F, 8616A, 18472A). 072407B 2007-2008 F-150 4X4, 1.9 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X4. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, 8509A,8620F, 8616A, 18472A). DEALER CODING CONDITION BASIC PART NO. CODE 8A616 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line Hose/Line HVAC: Service and Repair Compressor To Condenser Discharge Line COMPRESSOR TO CONDENSER DISCHARGE LINE Removal and Installation 1. Recover the refrigerant. 2. Detach the wire harness from the compressor-to-condenser discharge line. 3. Remove the A/C compressor discharge fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1354 4. Disconnect the A/C pressure transducer electrical connector. 5. Disconnect the condenser inlet fitting. - Discard the O-ring seal. - To install, tighten to 25 Nm (18 lb-ft). 6. Remove the compressor-to-condenser discharge line. 7. To install, reverse the removal procedure. - Install a new gasket seal and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 8. Evacuate, leak test and charge the refrigerant system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1355 Hose/Line HVAC: Service and Repair Condenser To Evaporator Line CONDENSER TO EVAPORATOR LINE Removal and Installation 1. Disconnect the battery. 2. Recover the refrigerant. 3. Remove the PCM. 4. Disconnect the A/C cycling switch electrical connector. 5. Remove the PCM bracket in the following sequence. 1 Remove the 3 PCM bracket bolts. 2 Remove the PCM bracket. - To install, tighten to 10 Nm (89 lb-in). 6. Disconnect the evaporator inlet fitting. - Discard the O-ring seals. 7. Disconnect the condenser outlet fitting. - Discard the O-ring seal. - To install, tighten to 25 Nm (18 lb-ft). 8. Remove the condenser to evaporator line. 9. To install, reverse the removal procedure. - Install new O-ring seals. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1356 - Lubricate the refrigerant system with the correct amount of clean PAG oil. 10. Evacuate, leak test and charge the refrigerant system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1357 Hose/Line HVAC: Service and Repair Suction Accumulator To Compressor Line SUCTION ACCUMULATOR TO COMPRESSOR LINE Removal and Installation 1. Recover the refrigerant. 2. Remove the A/C compressor suction fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). 3. Remove the suction accumulator outlet fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 8 Nm (71 lb-in). 4. Remove the suction accumulator-to-compressor line. 5. To install, reverse the removal procedure. - Install a new gasket seal and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 6. Evacuate, leak test and charge the refrigerant system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 07-21-3 > Oct > 07 > Power Steering - Cold Weather High Pressure Line Leakage Power Steering Line/Hose: Customer Interest Power Steering - Cold Weather High Pressure Line Leakage TSB 07-21-3 10/29/07 HIGH PRESSURE POWER STEERING LINE SEEPAGE - COLD CLIMATES ONLY (EXCLUDING HERITAGE F-150) FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT ISSUE Some 2004-2008 F-150 (Excluding Heritage F-150) and 2006-2008 Mark LT vehicles may encounter a concern of a power steering fluid seepage from tears in the high pressure line hose material due to prolonged exposure to -20 °F (-29 °C) and below, specifically climates in areas such as Alaska and Northern Canada. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new service only part has been developed which will resolve this concern on vehicles operating in this environment. Use of the part in warmer climates may result in increased incidents of steering shudder. Remove and replace the power steering line with the service only part listed, following Work Shop Manual, Section 211-02. NOTE USE OF THIS PART IN WARMER CLIMATES COULD RESULT IN LOW SPEED STEERING SHUDDER AND OTHER NVH RELATED COMPLAINTS. NOTE WHILE REPAIRING THE POWER STEERING SYSTEM, CARE SHOULD BE TAKEN TO PREVENT THE ENTRY OF FOREIGN MATERIAL OR FAILURE OF THE POWER STEERING COMPONENTS MAY RESULT. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072103A 2005-2008 F150 4.2L: 0.8 Hr. Replace The Power Steering Pressure Hose (Do Not Use With 3719A) 072103A 2005-2008 F150 4.6L: 1.4 Hrs. Replace The Power Steering Pressure Hose (Do Not Use With 3719A) 072103A 2005-2008 F150 1.1 Hrs. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 07-21-3 > Oct > 07 > Power Steering - Cold Weather High Pressure Line Leakage > Page 1366 2006-2008 Mark LI 5.4L 3V: Replace The Power Steering Pressure Hose (Do Not Use With 3719A) DEALER CODING CONDITION BASIC PART NO. CODE 3A719 D4 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 07-21-3 > Oct > 07 > Power Steering Cold Weather High Pressure Line Leakage Power Steering Line/Hose: All Technical Service Bulletins Power Steering - Cold Weather High Pressure Line Leakage TSB 07-21-3 10/29/07 HIGH PRESSURE POWER STEERING LINE SEEPAGE - COLD CLIMATES ONLY (EXCLUDING HERITAGE F-150) FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT ISSUE Some 2004-2008 F-150 (Excluding Heritage F-150) and 2006-2008 Mark LT vehicles may encounter a concern of a power steering fluid seepage from tears in the high pressure line hose material due to prolonged exposure to -20 °F (-29 °C) and below, specifically climates in areas such as Alaska and Northern Canada. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new service only part has been developed which will resolve this concern on vehicles operating in this environment. Use of the part in warmer climates may result in increased incidents of steering shudder. Remove and replace the power steering line with the service only part listed, following Work Shop Manual, Section 211-02. NOTE USE OF THIS PART IN WARMER CLIMATES COULD RESULT IN LOW SPEED STEERING SHUDDER AND OTHER NVH RELATED COMPLAINTS. NOTE WHILE REPAIRING THE POWER STEERING SYSTEM, CARE SHOULD BE TAKEN TO PREVENT THE ENTRY OF FOREIGN MATERIAL OR FAILURE OF THE POWER STEERING COMPONENTS MAY RESULT. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072103A 2005-2008 F150 4.2L: 0.8 Hr. Replace The Power Steering Pressure Hose (Do Not Use With 3719A) 072103A 2005-2008 F150 4.6L: 1.4 Hrs. Replace The Power Steering Pressure Hose (Do Not Use With 3719A) 072103A 2005-2008 F150 1.1 Hrs. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 07-21-3 > Oct > 07 > Power Steering Cold Weather High Pressure Line Leakage > Page 1372 2006-2008 Mark LI 5.4L 3V: Replace The Power Steering Pressure Hose (Do Not Use With 3719A) DEALER CODING CONDITION BASIC PART NO. CODE 3A719 D4 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose Power Steering Line/Hose: Service and Repair Steering Gear to Fluid Cooler Return Hose Steering Gear to Fluid Cooler Return Hose Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 1375 Part 2 Removal and Installation 1. CAUTION: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result. With the vehicle in NEUTRAL, position it on a hoist. 2. Using a suitable suction device, remove the power steering fluid from the fluid reservoir. 3. Remove the steering line clamp plate bolt, rotate the clamp plate and disconnect the return line. ^ To install, tighten to 23 Nm (17 lb-ft). 4. Release the clamp, disconnect the return hose from the power steering fluid cooler and remove the return line. 5. To install, reverse the removal procedure. ^ Fill the power steering system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 1376 Power Steering Line/Hose: Service and Repair Power Steering Pump to Steering Gear Pressure Line Power Steering Pump to Steering Gear Pressure Line Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 1377 Part 2 Removal 1. CAUTION: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the power steering pump pulley. 3. Remove the steering line clamp plate bolt and rotate the plate. 4. Disconnect the pressure line from the steering gear. 5. Remove the pressure line bracket-to-crossmember bolt. 6. Remove the pressure line bracket-to-engine nut. 7. Disconnect the pressure line-to-pump fitting and remove the pressure line. Installation 1. Position the pressure line and connect the pressure line-to-pump fitting. ^ If equipped with 4.6L or 5.4L engine, tighten to 65 Nm (48 lb-ft). ^ If equipped with 4.2L engine, tighten to 20 Nm (15 lb-ft). 2. Install the pressure line bracket-to-engine nut. ^ If equipped with a 4.2L or 4.6L engine, tighten the nut to 12 Nm (9 lb-ft). ^ If equipped with a 5.4L engine, tighten the nut to 40 Nm (30 lb-ft). 3. Install the pressure line bracket-to-crossmember bolt. ^ Tighten to 11 Nm (8 lb-ft). 4. Position the pressure line on the steering gear. 5. Rotate the steering line clamp plate and install the bolt. ^ Tighten to 23 Nm (17 lb-ft). 6. Install the power steering pump pulley. 7. Fill the power steering system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID AND CLUTCH FLUID Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid Ford Part Number: .......................... .............................................................................................................................................................. ....... PM-1-C Ford Specification: ......................................................................................................... ......................................................................... WSS-M6C62-A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Capacity Specifications Clutch Fluid: Capacity Specifications Between MIN/MAX on brake fluid reservoir and to the line or step on clutch fluid reservoir. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Capacity Specifications > Page 1386 Clutch Fluid: Fluid Type Specifications BRAKE FLUID AND CLUTCH FLUID Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid Ford Part Number: .......................... .............................................................................................................................................................. ....... PM-1-C Ford Specification: ......................................................................................................... ......................................................................... WSS-M6C62-A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine Coolant 4.2 ........................................................................................................................................................ .................................................... 17.6 quarts (16.7L) 4.6 ................................................................... ......................................................................................................................................... 20.5 quarts (19.4L) 5.4 ........................................................................................................................................... ................................................................. 20.9 quarts (19.8L) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1391 Coolant: Fluid Type Specifications ENGINE COOLANT Motorcraft Premium Gold Engine Coolant with bittering agent (yellow-colored) Ford Part Number: .. .............................................................................................................................................................. .................................. VC-7-B Ford Specification: ............................................................................... ................................................................................................. WSS-M97B51-A1 NOTE: Add the coolant type originally equipped in your vehicle. RECYCLED ENGINE COOLANT Ford Motor Company does NOT recommend the use of recycled engine coolant in vehicles originally equipped with Motorcraft Premium Gold Engine Coolant since a Ford-approved recycling process is not yet available. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid .............................................................................................................................. .................................................... 13.9 quarts (13.2L) NOTE: Approximate dry fill capacity including transmission fluid cooling system, actual refill capacities will vary based on vehicle application and transmission fluid cooling system (i.e. coolers size, cooling lines, auxiliary cooler capacities). The amount of transmission fluid and fluid level should be set by the indication on the dipsticks normal operating range. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1396 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ............................................ MERCON V XT-5-QM Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill Fluid - A/T: Service and Repair Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill Draining, all vehicles using a suitable flush and fill machine CAUTION: Always refer to the instructions supplied with the flush and fill machine, or transmission damage may occur. NOTE: Draining fluid from the transmission by removing only the transmission fluid pan is acceptable for normal or severe duty transmission fluid maintenance. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Use a suitable flush and fill machine to change the transmission fluid. 3. When connecting the flush and fill machine, connect the machine to the transmission fluid cooler tube after the transmission fluid cooler on the transmission fluid cooler return tube. This will help remove any foreign material trapped in the transmission fluid coolers. Refill 1. Use only clean transmission fluid. 2. Once the transmission fluid exchange has been completed, disconnect the flush and fill machine. Reconnect any disconnected transmission fluid cooler tubes. 3. With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved (transmission fluid should be in the cross-hatched area of the transmission fluid level indicator). Draining, all vehicles not using a suitable flush and fill machine 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Loosen the transmission fluid pan bolts and allow the transmission fluid to drain. 3. After the transmission fluid has drained, remove the transmission fluid pan. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 1399 4. Do not remove the transmission fluid filter. It is not necessary to change the transmission fluid filter during a normal maintenance transmission fluid change. 5. Clean and inspect the transmission fluid pan, transmission fluid pan gasket and magnet. 6. Thoroughly flush the transmission fluid cooler tubes. Refill 1. Position the magnet into the transmission fluid pan. 2. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and transmission fluid pan gasket. 1 Position the transmission fluid pan with the transmission fluid pan gasket in place. 2 Install the bolts. ^ Tighten to 14 Nm (10 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 1400 3. CAUTION: The use of any other transmission fluid can result in the transmission failing to operate in a normal manner or transmission failure. Fill the transmission. ^ Add 4.7L (5 qt) of clean transmission fluid to the transmission through the transmission fluid filler tube. 4. Start the engine. Move the selector lever through all the gear ranges, checking for engagements. 5. With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved (transmission fluid should be in the cross-hatched area of the transmission fluid level indicator). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 1401 Fluid - A/T: Service and Repair Transmission Fluid Cooler Backflushing and Cleaning Transmission Fluid Cooler Backflushing and Cleaning 1. CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail; this will effect the operation of the transmission. Conduct backflushing with a suitable torque converter/fluid cooler cleaner. Test your equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new filter in the flush equipment if flow is weak or contaminated. 2. If equipped, remove and discard the transmission fluid in-line filter. 3. Remove the transmission fluid cooler bypass valve and install rubber hoses in its place. 4. To aid in attaching the cleaner to the transmission steel cooler tubes, connect 2 additional rubber hoses to the transmission end of the steel transmission cooler tubes. ^ Connect the cleaner tank pressure tubes to the steel transmission cooler return tubes (longest tube). ^ Connect a tank return hose to the steel transmission cooler pressure tubes (shorter tube). Place the outlet end of this hose in the tank reservoir. 5. Turn on the pump and allow the transmission fluid to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in cooler system). 6. Switch off the pump and disconnect the pressure hose from the transmission cooler return tube. 7. Use compressed air to blow out the cooler(s) and tubes (blow air into the transmission cooler return tubes) until all fluid is removed. 8. Remove the rubber return hose from the remaining steel cooler tube. 9. Remove the rubber hoses and reinstall the transmission fluid cooler bypass valve. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transmission Capacity ............................................................................................................................................... ................................................................... 3.7 Quarts Note: Approximate refill. Service refill capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a level surface. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1406 Fluid - M/T: Fluid Type Specifications Manual Transmission Fluid .................................................................................................................. ......................................................... Mercon V ATF Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 1407 Fluid - M/T: Service and Repair Transmission Draining and Filling 1. NOTE: Position a suitable drain pan under the transmission. Remove the drain plug and drain the transmission. 2. Clean and reinstall the drain plug. ^ Tighten to 48 Nm (35 lb-ft). 3. NOTE: Clean the area around the filler plug. Remove the filler plug. 4. NOTE: Fill the transmission with the vehicle on a level surface. Using a suitable oil suction gun, fill the transmission to the correct level with the specified fluid. The fluid must be just below the fill plug hole. ^ Transmission capacity is 3.5L (3.1 qt). 5. Install the filler plug. ^ Tighten to 48 Nm (35 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity FRONT AXLE 4x4 vehicles ................................................................................................................. .................................................................................. 3.5 pints (1.8L) REAR AXLE 8.8/9.75 inch axle ........................................................................................................... ............................................................................... 5.5 pints (2.6L) 10.25 inch axle ........................... .............................................................................................................................................................. ..... 6.9 pints (3.3L) NOTE: Service refill capacity is determined by filling the axle to 1/4-9/16 inch (6-14 mm) below the bottom of the filler hole with the vehicle on a level surface. Add 4 oz. (118 ml) of Additive Friction Modifier XL3 or equivalent meeting Ford specification EST-M2C118A, for complete fill of 8.8 inch and 9.75 inch Traction-Lok axles. NOTE: Service refill capacity is determined by filling the axle to the bottom of the filler hole with the vehicle on a level surface. For 10.25 inch Traction-Lok axles, use 6.5 pints (3.1L) of Motorcraft SAE 75W-140 Synthetic Rear Axle Lubricant and 8 oz. (236 ml) of Additive Friction Modifier XL3 or equivalent meeting Ford Specification EST-M2C118-A. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1412 Fluid - Differential: Fluid Type Specifications REAR 8.8 / 9.75 / 10.25 AXLE Rear axle.......................................................................................................................................Motorcraft SAE 75W-140 Synthetic Rear Axle Lubricant Ford Part Number......................................................... ...........................................................................XY-75W140-QL(US) / CXY-75W140-1L(Canada) Ford Specification................................................................................................................................. ........................................................WSL-M2C192-A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Capacity 4.2L Engine ......................................................................................................................................... ............................................................ 5.68L (6.0 qt)* 4.6L Engine ......................................................................................................................................... .............................................................. 5.7L (6.0 qt)* * With filter. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1417 Engine Oil: Fluid Type Specifications Engine Oil U.S. ........................................................................................................................................ Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil Canada ................................................................................................................................................... Motorcraft SAE 5W-20 Super Premium Motor Oil Ford Part Number: ................................................................................................................................ XO-5W20-QSP (US), CXO-5W20LSP12 (Canada) Ford Specification: .................................................................................................................................................. WSS-M2C930-A and API Certification NOTE: Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only meet the requirements of Ford specification WSS-M2C930-A and the API Certification mark. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications Power Steering Fluid: .......................................................................................................................... ...................................... Motorcraft MERCON ATF Ford Part Number: .............................................. .................................................................................................................................................. XT-5-QM Ford Specifications: ............................................................................................................. .............................................................................. MERCON V Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page 1421 Power Steering Fluid: Testing and Inspection Power Steering Fluid Leak Test NOTE: This test should only be carried out if a leak in the system has not been detected during a thorough visual inspection. Refer to Inspection and Verification. See: Steering and Suspension/Steering/Testing and Inspection/Initial Inspection and Diagnostic Overview/Inspection and Verification 1. Check the power steering fluid level. If necessary, add the specified power steering fluid. 2. Remove the power steering pump reservoir cap and tightly install the evacuation cap to the power steering pump reservoir. 3. Install the hose from the fill adapter manifold tee to the evacuation cap on the power steering pump reservoir. 4. Install the vacuum pump to the evacuation cap. 5. Using the vacuum pump, apply 68-85 kPa (20-25 in-Hg) of vacuum to the power steering system. 6. Observe the vacuum gauge for 30 seconds. If the vacuum gauge reading drops more than 3 kPa (0.88 in-Hg) a leak is present. 7. Remove the vacuum pump. 8. CAUTION: Do not hold the steering wheel at the stops for an extended amount of time. Damage to the power steering pump may occur. Start the engine. With the engine at idle, raise the power steering fluid temperature to 74-80°C (165-176°F) by rotating the steering wheel fully to the left and right several times. 9. Visually inspect the system for leaks. If a leak is evident, repair as necessary. If a leak is not evident, add the specified UV fluorescent tracer dye to the power steering fluid. Use 14.78 mL (1/2 oz) of dye solution for every 1.89L (2 qt) of power steering fluid. 10. CAUTION: Do not hold the steering wheel at the stops for an extended amount of time. Damage to the power steering pump may occur. Start the engine. With the engine at idle, raise the power steering fluid temperature to 74-80°C (165-176°F) by rotating the steering wheel fully to the left and right several times. 11. Using the special tool (UV lamp), inspect the system for traces of UV dye. Repair as necessary. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R-1134a Refrigerant YN-19 (US): CYN-16-P or CYN-16-R (Canada)...........................WSH-M17B19-A (Specification) - 0.96 kg (34 oz) (Fill Capacity) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1426 Refrigerant: Fluid Type Specifications R-1134a Refrigerant YN-19 (US): CYN-16-P or CYN-16-R (Canada)...........................WSH-M17B19-A (Specification) - 0.96 kg (34 oz) (Fill Capacity) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant compressor Oil (R-134a Systems) YN-12-D................................................WSH-M1C231-B (Specification) - 237 ml (8 fl oz.) (Fill Capacity) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1431 Refrigerant Oil: Fluid Type Specifications Refrigerant compressor Oil (R-134a Systems) YN-12-D................................................WSH-M1C231-B (Specification) - 237 ml (8 fl oz.) (Fill Capacity) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding Brake Bleeding: Service and Repair Component Bleeding Component Bleeding Material Master Cylinder WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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. NOTE: When a new brake master cylinder has been installed or the system has been emptied or partially emptied, it should be primed to prevent air from getting into the system. 1. Disconnect the brake master cylinder outlet tubes. 2. NOTE: Original equipment tubes are not intended to be used during this procedure. Install short brake tubes with the ends submerged into the brake master cylinder reservoir and fill the brake master cylinder reservoir with clean, specified brake fluid. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1436 3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air bubbles. 4. Remove the short brake tubes and install the brake outlet tubes. 5. Bleed each brake tube at the brake master cylinder in the following sequence: 1 Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2 Loosen the rear brake tube fitting until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the brake tube fitting. 3 Repeat this operation until clear, bubble-free fluid comes out. 4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation for the front brake tube. 6. While the assistant maintains pressure on the brake pedal, tighten the brake tube fittings. ^ Tighten to 18 Nm (13 lb-ft). Brake Caliper WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If spilled, wipe up immediately before damage to the painted or plastic surface occurs. 1. Remove the brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the brake caliper bleeder screw to 20 Nm (15 lb ft), remove the rubber hose and install the bleeder screw cap. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1437 Brake Bleeding: Service and Repair Brake System Bleeding Brake System Bleeding Special Tool(s) Material WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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. NOTE: When the hydraulic control unit (HCU) or master cylinder is disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: Pressure bleed the brake system at 207-345 kPa (30-50 psi). NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. 1. Clean all the dirt from around the brake fluid reservoir cap and remove the cap. Fill the brake master cylinder reservoir with clean, specified brake fluid. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1438 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough clean, specified brake fluid to complete the bleeding operation. Remove the RH rear brake caliper bleeder cap and place a box end wrench on the bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear brake caliper bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw. ^ Press and release the parking brake 5 times. ^ Repeat until clear, bubble-free fluid comes out. 6. Tighten the RH rear brake caliper bleeder screw to 20 Nm (15 lb-ft), remove the rubber hose and install the bleeder screw cap. 7. Repeat Steps 5 and 6 for the LH rear brake caliper. ^ Tighten the LH rear brake caliper bleeder screw to 20 Nm (15 lb-ft). 8. Continue bleeding the front of the system, going in order from the RH front brake caliper and then to the LH front brake caliper. ^ Tighten the front brake caliper bleeder screws to 20 Nm (15 lb ft). 9. Close the bleeder tank valve. Remove the tank hose from the adapter and remove the adapter. Fill the reservoir with clean, specified brake fluid and install the reservoir cap. Manual Bleeding WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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. NOTE: When the hydraulic control unit (HCU) or master cylinder is disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with clean, specified brake fluid. 2. NOTE: Bleed the brake system from the longest to the shortest brake line. Remove the RH rear brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1439 4. Loosen the RH rear brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 5. Tighten the RH rear brake caliper bleeder screw to 20 Nm (15 lb-ft), remove the rubber hose and install the bleeder screw cap. 6. Repeat Steps 2 through 5 for the LH rear brake caliper bleeder screw. ^ Tighten the LH rear brake caliper bleeder screw to 20 Nm (15 lb-ft). 7. Remove the RH front brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9. Loosen the RH front brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 10. Tighten the RH front brake caliper bleeder screw to 20 Nm (15 lb-ft), remove the rubber hose and install the bleeder screw cap. 11. Repeat Steps 7 through 10 for the LH front brake caliper bleeder screw. ^ Tighten the LH front brake caliper bleeder screw to 20 Nm (15 lb-ft). ABS Hydraulic Control Unit (HCU) Bleeding WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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. NOTE: When the hydraulic control unit (HCU) or master cylinder is disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: This procedure is only required when a new HCU is installed. 1. NOTE: Carrying out the System Bleed function drives trapped air from the HCU. Subsequent bleeding removes the air from the brake hydraulic system through the bleeder screws. NOTE: Adequate voltage to the HCU module is required during the anti-lock control portion of the system bleed. Connect the scan tool to the vehicle. 2. Access the ABS HCU bleed function and follow the directions on the scan tool. 3. Manually bleed the brake hydraulic system. 4. Repeat the procedure carrying out a total of 2 scan tool cycles and 2 manual bleed cycles. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) Depowering Procedure WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, remove the trim panel, the cover and the RCM fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install the RCM fuse 19 (10A) to the CJB and install the cover and trim panel. 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1444 4. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1445 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, remove the trim panel, the cover, and the RCM fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Remove the driver air bag module. 8. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1446 9. While pushing in on the 2 glove compartment door tabs, position the glove compartment downward. 10. Through the glove compartment opening, release the tabs and disconnect the LH passenger air bag module electrical connector. 11. Attach the restraint system diagnostic tool to the vehicle harness side of the LH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1447 12. Through the glove compartment opening, release the tabs and disconnect the RH passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the RH passenger air bag module electrical connector. 14. Install the RCM fuse 19 (10A) to the CJB. 15. Connect the battery ground cable. Reactivation 1. Remove the RCM fuse 19 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the RH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1448 4. Through the glove compartment opening, connect the RH passenger air bag module electrical connector. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the LH passenger air bag module electrical connector. 6. Through the glove compartment opening, connect the LH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1449 7. Close the glove compartment. 8. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 9. Turn the ignition switch from OFF to ON. 10. Install the RCM fuse 19 (10A) to the CJB and install the cover and trim panel. 11. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 12. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse: Locations Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1455 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1456 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1457 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1458 Fuse: Locations Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1461 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1462 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1463 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1464 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1465 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1466 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1467 Fuse: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1468 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1469 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1470 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1471 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1472 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1473 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1476 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1477 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1478 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1479 Fuse: Application and ID Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1484 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1485 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1486 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1487 Fuse Block: Locations Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1490 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1491 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1492 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1493 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1494 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1495 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1496 Fuse Block: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1497 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1498 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1499 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1500 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1501 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1502 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1503 Fuse Block: Connector Views C270A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1504 C270B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1505 C270C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1506 C270D Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1507 C270E Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1508 C270F C270G Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1509 C270H Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1510 C270J Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1511 C270K Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1512 C270M Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1513 C270N C270P Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1516 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1517 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1518 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1519 Fuse Block: Application and ID Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1524 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1525 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1526 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1527 Relay Box: Locations Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1528 Relay Box: Diagrams C270A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1529 C270B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1530 C270C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1531 C270D Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1532 C270E Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1533 C270F C270G Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1534 C270H Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1535 C270J Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1536 C270K Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1537 C270M Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1538 C270N C270P Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1541 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1542 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1543 Relay Box: Application and ID Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 1544 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages Low Tire Pressure Indicator: Testing and Inspection Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages > Page 1550 Low Tire Pressure Indicator: Testing and Inspection Tire Pressure Monitoring System (TPMS) Indicator Illuminates Continuously Tire Pressure Monitoring System (TPMS) Indicator Illuminates Continuously NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPMS functionality before carrying out any diagnosis. NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressures for front and rear tires, tire rotation will not affect the system. 1. The TPMS indicator remains on continuously for the following condition: ^ Low Tire Pressure - The TPMS indicator is illuminated solid and the message center displays LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low. When this condition exists, the tire pressure must be adjusted to the recommended cold pressure as indicated on the vehicle certification label. 2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been stationary for more than 30 minutes, it will be necessary to wake up the sensors so they will transmit the latest tire pressure information to the VSM. If the vehicle has been stationary for more than 30 minutes, refer to the Tire Pressure Monitoring System (TPMS) Sensor Activation procedure. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages > Page 1551 Low Tire Pressure Indicator: Testing and Inspection Tire Pressure Monitoring System (TPMS) Indicator Flashes Tire Pressure Monitoring System (TPMS) Indicator Flashes The TPMS indicator flashes for 70 seconds and then remains ON solid when the ignition key is turned to the ON position for the following conditions: 1. Tire Pressure Sensor Fault - If equipped, the message center will display TIRE SENSOR FAULT when a tire pressure sensor is malfunctioning. GO to Symptom Chart. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures 2. No communication with the VSM (TPMS is integral to the VSM) - The TPMS indicator is illuminated when the instrument cluster has received no signals from the VSM for more than 5 seconds. If equipped, the message center displays TIRE MONITOR FAULT. GO to Symptom Chart. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures 3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE MONITOR FAULT when the tire pressure monitoring system is malfunctioning or communication with the instrument cluster has been lost. GO to Symptom Chart. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair SERVICE ENGINE SOON INDICATOR The Service engine soon indicator light illuminates when the ignition is first turned to the "ON" position to check the bulb. Solid illumination after the engine is started indicates the On Board Diagnostics System (OBD-II) has detected a malfunction. If the light is blinking, engine misfire is occurring which could damage your catalytic converter. Drive in a moderate fashion (avoid heavy acceleration and deceleration) and have your vehicle serviced immediately. CAUTION: Under engine misfire conditions, excessive exhaust temperatures could damage the catalytic converter, the fuel system, interior floor coverings or other vehicle components, possibly causing a fire. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) Check Engine, Service Engine Soon, Or ISO Standard Engine Symbol The MIL notifies the driver that the powertrain control module (PCM) has detected an on board diagnostic (OBD) emission-related component or system concern. When this occurs, an OBD diagnostic trouble code (DTC) sets. - The MIL is located in the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or the international standards organization (ISO) standard engine symbol. - The MIL is illuminated during the instrument cluster prove out for approximately 4 seconds. - The MIL remains illuminated after instrument cluster prove out if: an emission-related concern and DTC exists. - the PCM does not send a control message to the instrument cluster (applications with the MIL controlled through the communication link). - the PCM is operating in the hardware limited operation strategy (HLOS). - The MIL remains off during the instrument cluster prove out if an indicator or instrument cluster concern is present. - To turn off the MIL after a repair, a reset command from the scan tool must be sent, or 3 consecutive drive cycles must be completed without a concern. - For all MIL concerns, go to Symptom Charts. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures - If the MIL flashes at a steady rate, a severe misfire condition may exist. - If the MIL flashes erratically, the PCM can reset while cranking if the battery voltage is low. - The MIL flashes after a period of time with the key in the RUN position (engine not running) if DTC P1000 is set. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair Ford provides no information related to a Oil Change Reminder Lamp for this vehicle Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING AND LIFTING WARNING: - Never get underneath a vehicle that is supported only by a jack. The jack could unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions may result in serious personal injury. - Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand. Failure to follow this instruction may result in serious personal injury. - When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the parking brake if the rear wheels will remain on the ground. These actions help prevent unintended vehicle movement. Failure to follow these instructions may result in serious personal injury. - Position the hoist lift arms as shown in the illustration. Incorrect positioning could result in vehicle slipping or falling from the hoist. Failure to follow this instruction may result in serious personal injury. CAUTION: - Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack. - Position the jack to avoid contact with the fuel tank. Jacking Points - Front CAUTION: Do not use the control arm as a jacking point. Damage to the vehicle may occur. The jacking point is a flat portion on the frame, located behind the front tire and wheel assembly. Jacking Points - Rear CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 1565 The rear jacking points are located on the rear axle. Frame Lifting Points Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Locations Tire Pressure Module: Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Locations > Page 1570 View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Locations > Page 1571 Tire Pressure Module: Diagrams C3008A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Locations > Page 1572 C3008B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the vehicle security module (VSM). Refer to Tire Pressure Monitoring System (TPMS) Sensor Activation. See: Tire Monitoring System/Testing and Inspection/Programming and Relearning NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with tire pressure monitor system (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the activation tool, attempt to activate the same sensor with the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least 1/4 of a turn and attempt to activate the same sensor again. NOTE: The VSM has a 2 minute time limit between sensor responses. If the VSM does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the tire pressure must be adjusted and the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressures for front and rear tires, tire rotation will not affect the system. 1. NOTE: Click here to view an animated version of this procedure. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. ^ The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the activation tool must remain in place 180 degrees from the valve stem. Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the special tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the VSM. Click here to view an animated version of this procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1578 7. Within 2 minutes of the horn sounding, place the activation tool on the RF tire sidewall opposite (180°) from the valve stem to train the RF tire pressure sensor. 8. NOTE: Do not wait more than 2 minutes between training each sensor or the VSM will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor IDs trained to the VSM and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the VSM to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed VSM. If the sensors are being trained due to the installation of a new VSM, clear any DTCs and perform the VSM on-demand self test. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1579 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool against the LF tire sidewall 180 degrees from the tire valve stem. 3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the activation tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. 1. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. Click here to view an animated version of this procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1582 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. Click here to view an animated version of this procedure. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor may occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1583 3. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1584 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1585 Part 1 Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter, but all strap kits share the same base part number. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. Remove a factory installed strap in the following sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item on both sides of the buckle approximately 25 mm (0.98 in) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. 3. To remove a dealer-installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 4. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Click here to view an animated version of this procedure. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers may damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1586 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180 degrees from the valve stem. Click here to view a video version of this procedure. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. Click here to view an animated version of this procedure. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 in) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1587 6. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages Low Tire Pressure Indicator: Testing and Inspection Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages > Page 1593 Low Tire Pressure Indicator: Testing and Inspection Tire Pressure Monitoring System (TPMS) Indicator Illuminates Continuously Tire Pressure Monitoring System (TPMS) Indicator Illuminates Continuously NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPMS functionality before carrying out any diagnosis. NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressures for front and rear tires, tire rotation will not affect the system. 1. The TPMS indicator remains on continuously for the following condition: ^ Low Tire Pressure - The TPMS indicator is illuminated solid and the message center displays LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low. When this condition exists, the tire pressure must be adjusted to the recommended cold pressure as indicated on the vehicle certification label. 2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been stationary for more than 30 minutes, it will be necessary to wake up the sensors so they will transmit the latest tire pressure information to the VSM. If the vehicle has been stationary for more than 30 minutes, refer to the Tire Pressure Monitoring System (TPMS) Sensor Activation procedure. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages > Page 1594 Low Tire Pressure Indicator: Testing and Inspection Tire Pressure Monitoring System (TPMS) Indicator Flashes Tire Pressure Monitoring System (TPMS) Indicator Flashes The TPMS indicator flashes for 70 seconds and then remains ON solid when the ignition key is turned to the ON position for the following conditions: 1. Tire Pressure Sensor Fault - If equipped, the message center will display TIRE SENSOR FAULT when a tire pressure sensor is malfunctioning. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 2. No communication with the VSM (TPMS is integral to the VSM) - The TPMS indicator is illuminated when the instrument cluster has received no signals from the VSM for more than 5 seconds. If equipped, the message center displays TIRE MONITOR FAULT. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE MONITOR FAULT when the tire pressure monitoring system is malfunctioning or communication with the instrument cluster has been lost. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Locations Tire Pressure Module: Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Locations > Page 1598 View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Locations > Page 1599 Tire Pressure Module: Diagrams C3008A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Locations > Page 1600 C3008B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the vehicle security module (VSM). Refer to Tire Pressure Monitoring System (TPMS) Sensor Activation. See: Testing and Inspection/Programming and Relearning NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with tire pressure monitor system (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the activation tool, attempt to activate the same sensor with the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least 1/4 of a turn and attempt to activate the same sensor again. NOTE: The VSM has a 2 minute time limit between sensor responses. If the VSM does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the tire pressure must be adjusted and the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressures for front and rear tires, tire rotation will not affect the system. 1. NOTE: Click here to view an animated version of this procedure. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. ^ The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the activation tool must remain in place 180 degrees from the valve stem. Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the special tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the VSM. Click here to view an animated version of this procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1605 7. Within 2 minutes of the horn sounding, place the activation tool on the RF tire sidewall opposite (180°) from the valve stem to train the RF tire pressure sensor. 8. NOTE: Do not wait more than 2 minutes between training each sensor or the VSM will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor IDs trained to the VSM and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the VSM to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed VSM. If the sensors are being trained due to the installation of a new VSM, clear any DTCs and perform the VSM on-demand self test. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1606 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool against the LF tire sidewall 180 degrees from the tire valve stem. 3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the activation tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. 1. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. Click here to view an animated version of this procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1609 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. Click here to view an animated version of this procedure. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor may occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1610 3. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1611 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1612 Part 1 Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter, but all strap kits share the same base part number. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. Remove a factory installed strap in the following sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item on both sides of the buckle approximately 25 mm (0.98 in) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. 3. To remove a dealer-installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 4. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Click here to view an animated version of this procedure. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers may damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1613 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180 degrees from the valve stem. Click here to view a video version of this procedure. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. Click here to view an animated version of this procedure. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 in) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1614 6. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair Tires: Service and Repair Tire Rotation Rotating your tires at the recommended interval (as indicated in the Scheduled Maintenance Guide that comes with your vehicle) will help your tires wear more evenly, provided better tire performance and longer tire life. Sometimes irregular tire wear ran be corrected by rotating the tires. Note: If your tires show uneven wear ask an authorized dealer to check for and correct any wheel misalignment, tire imbalance or mechanical problem involved before tire rotation. Note: Your vehicle may be equipped with a dissimilar spare tire/wheel. A dissimilar spare tire/wheel is defined as a spare tire and/or wheel that is different in brand, site or appearance from the road tires and wheels. If you have a dissimilar spare tire/wheel it is intended for temporary use only and should not be used in a tire rotation. Note: After having your tires rotated, inflation pressure must be checked and adjusted to the vehicle requirements. If the tire label shows different tire pressures for the front and rear tires and the vehicle is equipped with TPMS (tire pressure monitoring system), Always perform the TPMS reset procedure after tire rotation. If the system is not reset, it may not provide a low tire pressure warning when necessary. See: Tire Monitoring System/Low Tire Pressure Indicator Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications SPINDLE BEARING LUBRICANT Premium Long-Life Grease Ford Part Number ..................................................................................................................................... XG-1-C or XG-1-K (US); CXG-1-C (Canada) Ford Specification .......................................................................... ............................................................................................................ ESA-M1C75-B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Wheel Bearing and Wheel Hub Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to make sure correct retention of these parts. 1. Remove the wheel and tire. 2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the 2 bolts and position the caliper and anchor plate assembly aside. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 200 Nm (148 lb-ft). 3. Remove the cotter pin and wheel hub nut retainer. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1623 ^ Discard the cotter pin. 4. Remove and discard the wheel hub nut. ^ To install, tighten to 400 Nm (296 lb-ft). 5. Remove the brake disc/wheel bearing and wheel hub assembly. 6. CAUTION: Do not apply lubricant to the threaded end of the wheel spindle or incorrect clamp load may occur. NOTE: Clean the wheel spindle (including the threaded end) of any dirt or grease using the specified solvent before installing the brake disc. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1624 Wheel Bearing: Service and Repair Rear Ford 8.8-Inch Ring Gear Rear Wheel Bearing and Axle Shaft Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1625 Removal 1. Remove the axle shaft. 2. NOTE: If the axle shaft oil seal is leaking, the axle housing vent may be plugged with foreign material. NOTE: Use care to avoid damaging the axle shaft oil seal bore. Using a suitable seal remover, remove and discard the axle shaft oil seal. 3. Inspect the rear wheel bearing and axle shaft for wear or damage. 4. If necessary, using the special tools, remove the rear wheel bearing. Installation 1. If removed, lubricate the new rear wheel bearing with axle lubricant. 2. If removed, use the special tools to install the rear wheel bearing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1626 3. Lubricate the lip of the new axle shaft oil seal with grease. 4. Using the special tools, install the new axle shaft oil seal. 5. Install the axle shaft. Ford 9.75-Inch Ring Gear Rear Wheel Bearing and Axle Shaft Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1627 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1628 Removal 1. Remove the axle shaft. 2. NOTE: If only a new axle shaft oil seal needs to be installed, use care to avoid damaging the axle shaft oil seal bore. Using a suitable seal remover, remove and discard the axle shaft oil seal. 3. Inspect the rear wheel bearing and axle shaft for wear or damage. 4. Using the special tools, remove the rear wheel bearing. Installation 1. Lubricate the new rear wheel bearing with axle lubricant. 2. Using the special tools, install the rear wheel bearing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1629 3. Lubricate the lip of the new axle shaft oil seal with grease. 4. Using the special tools, install the new axle shaft oil seal. 5. Install the axle shaft. Ford 10.25-Inch Ring Gear Rear Wheel Bearing and Axle Shaft Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1630 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1631 Removal 1. Remove the axle shaft. 2. NOTE: If only a new axle shaft oil seal needs to be installed, use care to avoid damaging the axle shaft oil seal bore. Using a suitable seal remover, remove and discard the axle shaft oil seal. 3. Inspect the rear wheel bearing and axle shaft for wear or damage. 4. Using the special tools, remove the rear wheel bearing. Installation 1. Lubricate the new rear wheel bearing with axle lubricant. 2. Using the special tools, install the rear wheel bearing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1632 3. Lubricate the lip of the new axle shaft oil seal with grease. 4. Using the special tools, install the new axle shaft oil seal. 5. Install the axle shaft. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations View 151-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 1637 C1291 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Nuts (With Vehicle Weight On Wheels) ..................................................................................................................... Tighten to 204 Nm (150 lb-ft) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING AND LIFTING WARNING: - Never get underneath a vehicle that is supported only by a jack. The jack could unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions may result in serious personal injury. - Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand. Failure to follow this instruction may result in serious personal injury. - When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the parking brake if the rear wheels will remain on the ground. These actions help prevent unintended vehicle movement. Failure to follow these instructions may result in serious personal injury. - Position the hoist lift arms as shown in the illustration. Incorrect positioning could result in vehicle slipping or falling from the hoist. Failure to follow this instruction may result in serious personal injury. CAUTION: - Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack. - Position the jack to avoid contact with the fuel tank. Jacking Points - Front CAUTION: Do not use the control arm as a jacking point. Damage to the vehicle may occur. The jacking point is a flat portion on the frame, located behind the front tire and wheel assembly. Jacking Points - Rear CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 1644 The rear jacking points are located on the rear axle. Frame Lifting Points Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 C1451 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 1652 C1452 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1653 Variable Valve Timing Actuator: Description and Operation VARIABLE CAMSHAFT TIMING (VCT) SYSTEM Overview The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are 4 types of VCT systems. - Exhaust phase shifting (EPS) system - the exhaust cam is the active cam being retarded. - Intake phase shifting (IPS) system - the intake cam is the active cam being advanced. - Dual equal phase shifting (DEPS) system - both intake and exhaust cams are phase shifted and equally advanced or retarded. - Dual independent phase shifting (DIPS) system - where both the intake and exhaust cams are shifted independently. All systems have 4 operational modes: idle, part throttle, wide open throttle (WOT), and default mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM) determines the phase angle based on air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque. In addition, some VCT system applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used. Variable Camshaft Timing (VCT) System VCT System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A crankshaft position (CKP) sensor provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, engine oil temperature (EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part and wide open throttle, the camshaft position is determined by engine RPM, load and throttle position. The VCT system does not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle. The PCM calculates and determines the desired camshaft position. It continually updates the VCT solenoid duty cycle until the desired position is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1654 disables the VCT and places the camshaft in a default position if a concern is detected. A related DTC is also set when the concern is detected. 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1658 Compression Check: Testing and Inspection Compression Test - Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of 5 compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1659 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75% of the highest reading. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Camshaft Bearing Cap Bolts ............................................................................................................... .................................................... 10 Nm (89 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures Camshaft: Procedures Camshaft Bearing Journal Diameter 1. Measure each camshaft journal diameter in 2 directions. Camshaft Journal to Bearing Clearance - Push Rod Engines 1. NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance. Measure each camshaft bearing in 2 directions. ^ Subtract the camshaft journal diameter from the camshaft bearing diameter. Camshaft Journal to Bearing Clearance OHC Engines 1. NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance. Measure each camshaft bearing in 2 directions. ^ Subtract the camshaft journal diameter from the camshaft bearing diameter. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1668 Camshaft End Play - Push Rod Engines Special Tool(s) 1. Remove the hydraulic lash adjusters. 2. Use a Dial Indicator Gauge with Holding Fixture to measure camshaft end play. 3. Position the camshaft to the rear of the cylinder block. 4. Zero the indicator. 5. Move the camshaft to the front of the cylinder block. Note and record the camshaft end play. Camshaft End Play - OHC Engines Special Tool(s) 1. Using the special tool, measure the camshaft end play. 2. Position the camshaft to the rear of the cylinder head. 3. Zero the indicator. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1669 4. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play. ^ If camshaft end play exceeds specifications, install a new camshaft and recheck end play. ^ If camshaft end play exceeds specification after camshaft installation, install a new cylinder head. Camshaft Surface Inspection 1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable outside the contact area. Camshaft Lobe Lift Special Tool(s) 1. Use an indicator gauge to measure camshaft intake/exhaust lobe lift. ^ Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading to figure the camshaft lobe lift. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1670 Camshaft Runout Special Tool(s) 1. NOTE: Camshaft journals must be within specifications before checking runout. Using the special tool, measure the camshaft runout. ^ Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1671 Camshaft: Removal and Replacement Camshafts Valve Train Components - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1672 Valve Train Components - Exploded View (Part 2) Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1673 Material Removal 1. Remove the timing drive components. 2. Install the special tool between the valve spring coils to protect the valve stem seal from damage. 3. CAUTION: The camshaft roller followers must be installed in their original locations. Record the camshaft roller follower locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. NOTE: The 3 rearmost camshaft roller followers on the RH side must use special tool 303-567 in the same manner as is shown in the illustration. Using the special tool, compress the valve spring and remove the camshaft roller follower. ^ Remove all of the camshaft roller followers from the camshaft being serviced. 4. Remove the bolt, camshaft sprocket and camshaft sprocket spacer from the camshaft being serviced. 5. Remove the special tools from the camshaft being serviced. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1674 6. Remove the bolts, camshaft bearing caps and the camshaft. 7. Clean and inspect the camshaft bearing caps. ^ One of the bearing caps contains an oil flow restriction groove. Make sure the groove is free of foreign material. Installation 1. Install the camshaft and the camshaft bearing caps in their original locations. ^ Lubricate the camshaft with clean engine oil. ^ Position the camshaft. ^ Lubricate the camshaft bearing caps with clean engine oil. ^ Position the camshaft bearing caps. ^ Install the bolts loosely. 2. NOTE: LH shown, RH similar. Tighten the bolts in the sequence shown. ^ Tighten to 10 Nm (89 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1675 3. Install the special tools on the camshaft being serviced. 4. Install the camshaft sprocket spacer, camshaft sprocket, washer and bolt onto the camshaft being serviced. Tighten the camshaft sprocket bolt in 2 stages: ^ Stage 1: Tighten to 40 Nm (30 lb-ft). ^ Stage 2: Tighten an additional 90 degrees. 5. Install the special tool between the valve spring coils to protect the valve stem seal from damage. 6. CAUTION: The camshaft roller followers must be installed in their original locations. Failure to follow these instructions may result in Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1676 engine damage. NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. NOTE: The 3 rearmost camshaft roller followers on the RH side must use special tool 303-567 in the same manner as is shown in the illustration. NOTE: Lubricate the camshaft roller follower with clean engine oil prior to installation. Using the special tool, compress the valve spring and install the camshaft roller follower. ^ Install all of the camshaft roller followers onto the camshaft being serviced. 7. Install the timing drive components. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Hydraulic Lash Adjuster Inspection Lifter / Lash Adjuster: Testing and Inspection Hydraulic Lash Adjuster Inspection Hydraulic Lash Adjuster Inspection 1. Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect the camshaft lobes and valves for damage. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Hydraulic Lash Adjuster Inspection > Page 1681 Lifter / Lash Adjuster: Testing and Inspection Valve Tappet Inspection Valve Tappet Inspection OHC engines 1. Inspect the valve tappet for damage, especially in the indicated areas. if any damage is evident, inspect the camshaft lobes and valves for damage. Replace components as necessary. Push rod engines Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Page 1682 Lifter / Lash Adjuster: Service and Repair Hydraulic Lash Adjuster Valve Train Components - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Page 1683 Valve Train Components - Exploded View (Part 2) Material Removal 1. Remove the camshaft roller followers. 2. CAUTION: The hydraulic lash adjusters must be installed in their original locations. Record the hydraulic lash adjuster locations. Failure to follow these instructions may result in engine damage. Remove the hydraulic lash adjusters. Installation 1. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil prior to installation. Install the hydraulic lash adjusters in their original locations. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Page 1684 2. Install the camshaft roller followers. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Testing and Inspection Push Rod: Testing and Inspection Push Rod Cleaning and Inspection Special Tool(s) 1. Clean the push rods in a suitable solvent. Blow out the oil passage in the push rods with compressed air. 2. NOTE: Do not attempt to straighten the push rods. Check the ends of the push rods for nicks, grooves, roughness or excessive wear. ^ The push rods can be checked for straightness while they are installed in the engine by rotating them with the valve closed. ^ They also can be checked using a Dial Indicator. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Testing and Inspection Rocker Arm Assembly: Testing and Inspection Roller Follower Inspection 1. Inspect the roller follower for flat spots or scoring. If any damage is found, inspect the camshaft lobes and hydraulic lash adjuster for damage. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures Rocker Arm Assembly: Procedures Rocker Arm Cleaning and Inspection 1. Clean all parts thoroughly. Make sure all oil passages are open. 2. Make sure the oil passage in the push rod/valve tappet end of the rocker arm is open. CAUTION: Do not attempt to true surfaces by grinding. Check the rocker arm pad, side rails and seat for excessive wear, cracks, nicks or burrs. Check the rocker arm seat bolt for stripped or broken threads. Install new components as necessary or engine damage may occur. 3. Inspect the rocker arm push rod bore for nicks, scratches, scores or scuffs. 4. Inspect the pad at the valve end of the rocker arm for indications of grooving, scuffing or abnormal wear. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1693 Rocker Arm Assembly: Removal and Replacement Camshaft Roller Follower Valve Train Components - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1694 Valve Train Components - Exploded View (Part 2) Special Tool(s) Material Removal 1. If servicing the LH cylinder valve train components, remove the LH valve cover. 2. If servicing the RH cylinder valve train components, remove the RH valve cover. 3. Position the piston of the cylinder being serviced at the bottom of the stroke. 4. Install the special tool between the valve spring coils to protect the valve stem seal from damage. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1695 5. CAUTION: The camshaft roller followers must be installed in their original locations. Record the camshaft roller follower locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. NOTE: The 3 rearmost camshaft roller followers on the RH side must use special tool 303-567 in the same manner as is shown in the illustration. Using the special tool, compress the valve springs and remove the camshaft roller follower. 6. Repeat the previous steps for each of the camshaft roller followers being serviced. Installation 1. Install the special tool between the valve spring coils to protect the valve stem seal from damage. 2. CAUTION: The camshaft roller followers must be installed in their original locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1696 NOTE: The 3 rearmost camshaft roller followers on the RH side must use special tool 303-567 in the same manner as is shown in the illustration. NOTE: Lubricate the camshaft roller follower with clean engine oil prior to installation. Using the special tool, compress the valve springs and install the camshaft roller follower. 3. Repeat the previous 3 steps for each camshaft roller follower being serviced. 4. If servicing the RH cylinder valve train components, install the RH valve cover. 5. If servicing the LH cylinder valve train components, install the LH valve cover. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 C1451 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 1701 C1452 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1702 Variable Valve Timing Actuator: Description and Operation VARIABLE CAMSHAFT TIMING (VCT) SYSTEM Overview The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are 4 types of VCT systems. - Exhaust phase shifting (EPS) system - the exhaust cam is the active cam being retarded. - Intake phase shifting (IPS) system - the intake cam is the active cam being advanced. - Dual equal phase shifting (DEPS) system - both intake and exhaust cams are phase shifted and equally advanced or retarded. - Dual independent phase shifting (DIPS) system - where both the intake and exhaust cams are shifted independently. All systems have 4 operational modes: idle, part throttle, wide open throttle (WOT), and default mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM) determines the phase angle based on air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque. In addition, some VCT system applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used. Variable Camshaft Timing (VCT) System VCT System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A crankshaft position (CKP) sensor provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, engine oil temperature (EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part and wide open throttle, the camshaft position is determined by engine RPM, load and throttle position. The VCT system does not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle. The PCM calculates and determines the desired camshaft position. It continually updates the VCT solenoid duty cycle until the desired position is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1703 disables the VCT and places the camshaft in a default position if a concern is detected. A related DTC is also set when the concern is detected. 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearing bore diameter ............................................................................................................................................. 56.756-56.876 mm (2.234-2.24 inch) Bearing-to-crankshaft clearance .............................................................................................................................. 0.027-0.069 mm (0.001-0.0027 inch) Side clearance (assembled to crank) Standard ............................................................................................................................................................ 0.015-0.45 mm (0.0006-0.0177 inch) Service limit .............................................................................. ........................................................................................ 0.05 mm (0.002 inch) max. Crankshaft Connecting Rod Journal Diameter ............................................................................................................................................................ 52.983-53.003 mm (2.0859-2.0867 inch) Maximum taper .................................................................. .......................................................................................................... 0.004 mm (0.0002 inch) Maximum out-of-round ........................................................................................................................ ........................................ 0.006 mm (0.0002 inch) Connecting Rod Cap Bolts Discard the bolts. First pass ............................................................................................................................................. .................................................... 43 Nm (32 lb-ft). Final pass ............................................................ ..................................................................................................................... Tighten an additional 105° Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1708 Connecting Rod Bearing: Testing and Inspection Bearing Inspection 1. Inspect bearings for the following defects: 1 Cratering - fatigue failure 2 Spot polishing - incorrect seating 3 Imbedded dirty engine oil 4 Scratching dirty engine oil 5 Base exposed - poor lubrication 6 Both edges worn - journal damaged 7 One edge worn journal tapered or bearing not seated Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting Rod Cap Bolts Discard the bolts. First pass ............................................................................................................................................. .................................................... 43 Nm (32 lb-ft). Final pass ............................................................ ..................................................................................................................... Tighten an additional 105° Connecting Rod Clearance-to-pin .................................................................................................................................................... 0.015-0.040 mm (0.0006-0.0016 inch) Pin bore diameter .................................................................................................................................................. 21.959-21.979 mm (0.864-0.865 inch) Length (center-to-center) ....................................................... .......................................................................................................... 150.7 mm (5.93 inch) Maximum allowed bend .................................................................................................................................. 0.038 mm per 25 mm (0.0015-0.984 inch) Maximum allowed twist (a) ............................................................................................................................. 0.050 mm per 25 mm (0.0015-0.984 inch) Bearing bore diameter ............................................................................................................................................. 56.756-56.876 mm (2.234-2.24 inch) Bearing-to-crankshaft clearance .............................................................................................................................. 0.027-0.069 mm (0.001-0.0027 inch) Side clearance (assembled to crank) Standard ............................................................................................................................................................ 0.015-0.45 mm (0.0006-0.0177 inch) Service limit .............................................................................. ........................................................................................ 0.05 mm (0.002 inch) max. (a) The pin bore and crank bearing bore must be parallel and in the same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 105.5 mm on each side of rod centerline. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1712 Connecting Rod: Service and Repair Connecting Rod Cleaning CAUTION: Do not use a caustic cleaning solution or damage to connecting rods can occur. 1. NOTE: The connecting rod large end is a matched set. The connecting rod cap must be installed on the original connecting rod in the original position. Do not reverse the cap. Parts are not interchangeable. Mark and separate the parts and clean with solvent. Clean the oil passages. Connecting Rod Large End Bore 1. Tighten the bolts to specification, then measure the bore in 2 directions. The difference is the connecting rod bore out-of-round. Verify the out-of-round is within specification. Connecting Rod Bushing Diameter 1. Use a telescoping gauge to determine the inner diameter of the connecting rod bushing, if equipped. 2. Measure the telescoping gauge with a micrometer. Verify the diameter is within specification. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1713 Connecting Rod Bend 1. Measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the bend measurement is within specification. Connecting Rod Twist 1. Measure the connecting rod twist on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the measurement is within specification. Connecting Rod to Crankshaft Side Clearance 1. Measure the clearance between the connecting rod and the crankshaft. Verify the measurement is within specification. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1714 Connecting Rod-to-Piston Clearance 1. Measure the clearance between the connecting rod and the piston. Verify the measurement is within specification. Connecting Rod Bearing Journal-to-Bearing Clearance NOTE: The crankshaft connecting rod journals must be within specifications to check the connecting rod bearing journal clearance. 1. Remove the connecting rod bearing cap. 2. Position a piece of Plastigage(R) across the bearing surface. 3. NOTE: Do not turn the crankshaft during this step. Install and tighten to specifications, then remove the connecting rod bearing cap. 4. Measure the Plastigage(R) to get the connecting rod bearing journal clearance. The Plastigage(R) should be smooth and flat. A changing width indicates a tapered or damaged connecting rod or connecting rod bearing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1715 Connecting Rod Bearing Journal Taper and Out-of-Round 1. Measure the crankshaft connecting rod journal diameters in 2 directions perpendicular to one another at each end of the connecting rod journal. The difference in the measurements from one end to the other is the taper. Verify measurement is within the wear limit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Pulley Bolt CAUTION: This bolt is torque-to-yield and cannot be reused. Failure to follow these instructions may result in engine damage. First pass ............................................................................................................................................. .................................................... 90 Nm (66 lb-ft). Second pass ........................................................ ................................................................................................................................ Loosen one full turn Third pass ..................................................................................................................................... .......................................................... 50 Nm (37 lb-ft). Final pass ..................................................................................................................... Tighten an additional 90° without exceeding 200 Nm (148 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Crankshaft Main bearing journal Diameter .............................................................................................................................................. ........................ 67.483-67.503 mm (2.65 inch) Maximum taper .......................................................... ............................................................................................................ 0.004 mm (0.0002 inch) Maximum out-of-round .............................................................................................................................................................. 0.06 mm (0.002 inch) Clearance-to-cylinder block ............................................................................................................................ 0.027-0.065 mm (0.0011-0.0026 inch) Connecting rod journal Diameter ...................................................................................................................................................... 52.983-53.003 mm (2.0859-2.0867 inch) Maximum taper .................................................................. .................................................................................................... 0.004 mm (0.0002 inch) Maximum out-of-round .......................................................................................................................................................... 0.006 mm (0.0002 inch) Maximum end play .................................................................................................................................................. 0.130-0.301 mm (0.0051-0.012 inch) Main bearing bore inside diameter ........................................................................................................................ 72.402-72.422 mm (2.850-2.851 inch) Vertical Main Bearing Cap Fasteners Discard the fasteners. First pass ............................................................................................................................................. .................................................... 40 Nm (30 lb-ft). Final pass ............................................................ ....................................................................................................................... Tighten an additional 90° Jack Screws Discard the screws. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1722 First pass ............................................................................................................................................. ..................................................... 5 Nm (44 lb-in). Final pass ............................................................ .................................................................................................................................... 10 Nm (89 lb-in). Side Bolts ............................................................................................................................................ ....................................................... 21 Nm (15 lb-ft). Discard the bolts. Crankshaft Main Bearing Codes Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1723 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1724 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1725 Crankshaft Main Bearing: Testing and Inspection Bearing Inspection 1. Inspect bearings for the following defects: 1 Cratering - fatigue failure 2 Spot polishing - incorrect seating 3 Imbedded dirty engine oil 4 Scratching dirty engine oil 5 Base exposed - poor lubrication 6 Both edges worn - journal damaged 7 One edge worn journal tapered or bearing not seated Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Crankshaft Main bearing journal Diameter .............................................................................................................................................. ........................ 67.483-67.503 mm (2.65 inch) Maximum taper .......................................................... ............................................................................................................ 0.004 mm (0.0002 inch) Maximum out-of-round .............................................................................................................................................................. 0.06 mm (0.002 inch) Clearance-to-cylinder block ............................................................................................................................ 0.027-0.065 mm (0.0011-0.0026 inch) Connecting rod journal Diameter ...................................................................................................................................................... 52.983-53.003 mm (2.0859-2.0867 inch) Maximum taper .................................................................. .................................................................................................... 0.004 mm (0.0002 inch) Maximum out-of-round .......................................................................................................................................................... 0.006 mm (0.0002 inch) Maximum end play .................................................................................................................................................. 0.130-0.301 mm (0.0051-0.012 inch) Main bearing bore inside diameter ........................................................................................................................ 72.402-72.422 mm (2.850-2.851 inch) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1729 Crankshaft: Service and Repair Crankshaft Main Bearing Journal Diameter 1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions. Crankshaft Main Bearing Journal Taper and Out-of-Round 1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions at each end of the main bearing journal. Crankshaft Main Bearing Journal-to-Bearing Clearance NOTE: Crankshaft main bearing journals must be within specifications before checking journal clearance. 1. Remove the crankshaft main bearing caps and crankshaft main bearing. 2. Lay a piece of Plastigage(R) across the face of each crankshaft main bearing surface. 3. NOTE: Do not turn the crankshaft while carrying out this procedure. Install and remove the crankshaft main bearing cap. 4. Verify the crankshaft journal clearance. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1730 Crankshaft End Play Special Tool(s) 1. Using the Dial Indicator Gauge, measure the crankshaft end play. 2. Position the crankshaft to the rear of the cylinder block. 3. Zero the indicator. 4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. Crankshaft Runout Special Tool(s) 1. NOTE: Crankshaft main bearing journals must be within specifications before checking runout. Use the Dial Indicator Gauge to measure the crankshaft runout. ^ Rotate the crankshaft and subtract the lowest dial indicator reading from the highest dial indicator reading to figure the crankshaft runout. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1731 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair Engine Block Heater: Service and Repair Block Heater Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding. 3. Disconnect the block heater electrical connector. 4. NOTE: Do not loosen the block heater retaining screw more than necessary for removal. Loosen the block heater retaining screw and remove the block heater. ^ To install, tighten to 2 Nm (18 lb-in). 5. NOTE: Clean the engine block mating surface with metal surface prep. Follow the directions on the packaging. To install, reverse the removal procedure. ^ Route the block heater power cable away from hot or rotating components, or damage to the cable can occur. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley Bolt CAUTION: This bolt is torque-to-yield and cannot be reused. Failure to follow these instructions may result in engine damage. First pass ............................................................................................................................................. .................................................... 90 Nm (66 lb-ft). Second pass ........................................................ ................................................................................................................................ Loosen one full turn Third pass ..................................................................................................................................... .......................................................... 50 Nm (37 lb-ft). Final pass ..................................................................................................................... Tighten an additional 90° without exceeding 200 Nm (148 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1738 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Pulley Special Tool(s) Material Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1739 Removal 1. Remove the cooling fan shroud. For additional information, refer to Cooling System. 2. Rotate the tensioner clockwise and remove the drive belt. 3. CAUTION: This bolt is torque-to-yield and cannot be reused. Failure to follow these instructions may result in engine damage. Using the special tool, remove the bolt and washer and discard the bolt. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1740 4. Using the special tool, remove the crankshaft pulley. Installation 1. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley. 2. Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1741 3. Using the special tool, install the crankshaft pulley. 4. Using a new crankshaft pulley bolt, install the crankshaft pulley bolt and washer. Using the special tool to hold the crankshaft pulley, tighten the bolt in 4 stages: ^ Stage 1: Tighten to 90 Nm (66 lb-ft). ^ Stage 2: Loosen one full turn. ^ Stage 3: Tighten to 50 Nm (37 lb-ft). ^ Stage 4: Tighten an additional 90 degrees without exceeding 200 Nm (148 lb-ft). 5. Rotate the tensioner clockwise and install the drive belt. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1742 6. Install the cooling fan shroud. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Diameter Coded red 1 ..................................................................................................................................................... 90.177-90.197 mm (3.550-3.551 inch) Coded blue 2 ............................................................................................................................................... 90.190-90.210 mm (3.5507-3.5515 inch) Coded yellow 3 ............................................................................................................................................. 90.203-90.223 mm (3.513-3.5521 inch) Clearance-to-cylinder bore .................................................................................................................................. 0.012-0.0026 mm (0.0005-0.0001 inch) Ring end gap Compression (top and bottom) ................................................................................................................................ 0.23-0.49 mm (0.010-0.020 inch) Oil ring (steel rail) ................................................................................................................................................... 0.05-0.66 mm (0.006-0.026 inch) Ring groove width Compression (top) ............................................................................................................................................... 1.520-1.550 mm (0.002-0.610 inch) Compression (bottom) ........................................................................................................................................ 1.520-1.530 mm(0.060-0.0602 inch) Oil ring .............................................................................................................................................................. 6.996-7.224 mm (0.275-0.2844 inch) Ring width Compression ........................................................................................................................................................ 1.49-1.47 mm (0.0587-0.0579 inch) Oil ring rail (2) ...................................................................................... 0.473-0.447 mm (0.0186-0.0176 inch), 0.483 mm (0.0190 inch) max. at ID Oil ring expander ................................................................................................................................................ 2.038-1.960 mm (0.080-0.077 inch) Ring-to-groove clearance Compression .................................................................................................................................................... 0.030-0.070 mm (0.0012-0.0028 inch) Oil ring assembly ............................................................................................................................................ 0.046-0.196 mm (0.0018-0.0077 inch) Pin Bore diameter .............................................................................................................................................. 22.0015-22.004 mm (0.866-0.8663 inch) Pin diameter ....................................................................... ........................................................................................................ 22.0 mm (0.866 inch) Length ...... .............................................................................................................................................................. .................... 61.8 mm (2.433 inch) Fit-to-piston ..................................................................................................................................................... 0.005-0.010 mm (0.0002-0.0004 inch) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures Piston: Procedures Piston Inspection Special Tool(s) CAUTION: Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage can occur. 1. Clean and inspect the (1) ring lands, (2) skirts, (3) pin bosses and the (4) tops of the pistons. If wear marks, scores or glazing is found on the piston skirt, check for a bent or twisted connecting rod. 2. Use the Piston Ring Groove Scraper to clean the piston ring grooves. ^ Make sure the oil ring holes are clean. Piston Pin Bore Diameter 1. WARNING: Since the retainer ring has a tendency to spring out, cover the end of the pin bore with a hand or shop rag when removing the ring. Wear eye protection. Failure to follow these instructions may result in serious personal injury. NOTE: Piston and piston pins are a matched set and should not be interchanged. Measure the piston pin bore diameter in 2 directions on each side. Verify the diameter is within specification. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1748 Piston Diameter 1. Measure the piston diameter 90 degrees from the piston pin and 42 mm (1.65 inch) down from the top of the piston at the point indicated. Piston To Cylinder Bore Clearance 1. Subtract the piston diameter from the cylinder bore diameter to find the piston-to-cylinder bore clearance. Piston Selection NOTE: The cylinder bore must be within the specifications for taper and out-of-round before fitting a piston. 1. Select a piston size based on the cylinder bore. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1749 2. NOTE: For precision fit, new pistons are divided into 3 categories within each size range based on their relative position within the range. A paint spot or specific size grade on a new piston indicates the position within the size range. Choose the piston with the correct paint color or specific size grade. Piston Ring End Gap CAUTION: Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore. NOTE: Piston rings should not be transferred from one piston to another. NOTE: The cylinder bore must be within specification for taper and out-of-round. 1. Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel. 2. Use a feeler gauge to measure the top piston ring end gap and the second piston ring end gap. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1750 Piston Ring-to-Groove Clearance 1. Inspect the piston for ring land damage or accelerated wear. 2. Measure the piston ring-to-groove clearance. Piston Pin Diameter 1. Measure the piston pin diameter in 2 directions at the points shown. Verify the diameter is within specification. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1751 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1752 Piston: Overhaul Piston Material Disassembly 1. Remove the upper piston compression ring. 2. Remove the lower piston compression ring. 3. Remove the upper piston oil control segment ring. 4. Remove the piston oil control spacer. 5. Remove the lower piston oil control segment ring. 6. Remove the 2 piston pin retainers. 7. Remove the piston pin and remove the connecting rod from the piston. Assembly Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1753 1. NOTE: The connecting rod must be installed into the piston with identification markings toward the front. Position the connecting rod in the piston. 2. NOTE: Lubricate the piston pin and retainers with clean engine oil. Install the piston pin and the 2 piston pin retainers. 3. NOTE: Lubricate all the piston rings and the piston oil control spacer with clean engine oil. Install the lower piston oil control segment ring. 4. Install the piston oil control spacer. 5. Install the upper piston oil control segment ring. 6. Install the lower piston compression ring. 7. Install the upper piston compression ring. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Rings Ring end gap Compression (top and bottom) ................................................................................................................................ 0.23-0.49 mm (0.010-0.020 inch) Oil ring (steel rail) ................................................................................................................................................... 0.05-0.66 mm (0.006-0.026 inch) Ring groove width Compression (top) ............................................................................................................................................... 1.520-1.550 mm (0.002-0.610 inch) Compression (bottom) ........................................................................................................................................ 1.520-1.530 mm(0.060-0.0602 inch) Oil ring .............................................................................................................................................................. 6.996-7.224 mm (0.275-0.2844 inch) Ring width Compression ........................................................................................................................................................ 1.49-1.47 mm (0.0587-0.0579 inch) Oil ring rail (2) ...................................................................................... 0.473-0.447 mm (0.0186-0.0176 inch), 0.483 mm (0.0190 inch) max. at ID Oil ring expander ................................................................................................................................................ 2.038-1.960 mm (0.080-0.077 inch) Ring-to-groove clearance Compression .................................................................................................................................................... 0.030-0.070 mm (0.0012-0.0028 inch) Oil ring assembly ............................................................................................................................................ 0.046-0.196 mm (0.0018-0.0077 inch) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance This engine is equipped with hydraulic lash adjusters. No adjustment is required. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE Special Tool(s) Special Tool(s) 1. NOTE: The splash shield is located on the LH frame rail under the driver side door. Disconnect the splash shield and position aside. 2. Disconnect the electrical connector. 3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition switch to the OFF position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Page 1764 6. When fuel system service is complete, connect the electrical connector. 7. Reposition the splash shield and install a new pushpin. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Install the scan tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON. Select the appropriate vehicle and engine qualifier. Clear all DTCs and carry out a PCM reset. 10. Start the vehicle and check the fuel system for leaks. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Testing and Inspection Rocker Arm Assembly: Testing and Inspection Roller Follower Inspection 1. Inspect the roller follower for flat spots or scoring. If any damage is found, inspect the camshaft lobes and hydraulic lash adjuster for damage. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures Rocker Arm Assembly: Procedures Rocker Arm Cleaning and Inspection 1. Clean all parts thoroughly. Make sure all oil passages are open. 2. Make sure the oil passage in the push rod/valve tappet end of the rocker arm is open. CAUTION: Do not attempt to true surfaces by grinding. Check the rocker arm pad, side rails and seat for excessive wear, cracks, nicks or burrs. Check the rocker arm seat bolt for stripped or broken threads. Install new components as necessary or engine damage may occur. 3. Inspect the rocker arm push rod bore for nicks, scratches, scores or scuffs. 4. Inspect the pad at the valve end of the rocker arm for indications of grooving, scuffing or abnormal wear. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1770 Rocker Arm Assembly: Removal and Replacement Camshaft Roller Follower Valve Train Components - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1771 Valve Train Components - Exploded View (Part 2) Special Tool(s) Material Removal 1. If servicing the LH cylinder valve train components, remove the LH valve cover. 2. If servicing the RH cylinder valve train components, remove the RH valve cover. 3. Position the piston of the cylinder being serviced at the bottom of the stroke. 4. Install the special tool between the valve spring coils to protect the valve stem seal from damage. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1772 5. CAUTION: The camshaft roller followers must be installed in their original locations. Record the camshaft roller follower locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. NOTE: The 3 rearmost camshaft roller followers on the RH side must use special tool 303-567 in the same manner as is shown in the illustration. Using the special tool, compress the valve springs and remove the camshaft roller follower. 6. Repeat the previous steps for each of the camshaft roller followers being serviced. Installation 1. Install the special tool between the valve spring coils to protect the valve stem seal from damage. 2. CAUTION: The camshaft roller followers must be installed in their original locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1773 NOTE: The 3 rearmost camshaft roller followers on the RH side must use special tool 303-567 in the same manner as is shown in the illustration. NOTE: Lubricate the camshaft roller follower with clean engine oil prior to installation. Using the special tool, compress the valve springs and install the camshaft roller follower. 3. Repeat the previous 3 steps for each camshaft roller follower being serviced. 4. If servicing the RH cylinder valve train components, install the RH valve cover. 5. If servicing the LH cylinder valve train components, install the LH valve cover. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH Valve Cover: Service and Repair Valve Cover - LH Valve Cover - LH Material Power Steering Reservoir, EGR and Crankcase Tube Connections Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 1778 LH Valve Cover and Gasket Removal 1. Remove the air cleaner outlet pipe and the air cleaner assembly. For additional information, refer to Fuel Delivery and Air Induction. 2. Remove the power steering reservoir support bracket-to-thermostat housing bolt. 3. Remove the 2 power steering reservoir support bracket-to-cylinder head bolts and position the power steering reservoir and support bracket assembly aside. 4. Remove the bolt and position the oil level indicator aside. 5. Disconnect the quick connect coupling and remove the crankcase ventilation tube. For additional information, refer to Fuel Delivery and Air Induction. 6. Remove the EGR system module-to-exhaust manifold tube. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 1779 7. Disconnect the 3 engine wiring harness retainers. 8. Remove the 5 LH valve cover studs. 9. Remove the 6 LH valve cover bolts. 10. Remove the LH valve cover bolt. 11. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Remove the LH valve cover. ^ Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. ^ Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent. Installation 1. Apply instant gel adhesive completely around the gasket groove in the valve cover and install the new valve cover gasket. 2. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head. 3. Position the valve cover and tighten the fasteners in the sequence shown to 10 Nm (89 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 1780 4. Connect the 3 engine wiring harness retainers. 5. Position the oil level indicator and install the bolt. ^ Tighten to 10 Nm (89 lb-in). 6. Install the EGR system module-to-exhaust manifold tube. ^ Tighten to 40 Nm (30 lb-ft). 7. Position the crankcase ventilation tube and connect the quick connect coupling. 8. Position the power steering reservoir and support bracket assembly and install the 2 power steering reservoir support bracket-to-cylinder head bolts. ^ Tighten to 25 Nm (18 lb-ft). 9. Install the power steering reservoir support bracket-to-thermostat housing bolt. ^ Tighten to 11 Nm (8 lb-ft). 10. Install the air cleaner outlet pipe and the air cleaner assembly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 1781 Valve Cover: Service and Repair Valve Cover - RH Valve Cover - RH Material Removal 1. Remove the suction accumulator. For additional information, refer to Heating and Air Conditioning. 2. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to Fuel Delivery and Air Induction. 3. Disconnect the PCV valve electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 1782 4. Disconnect the vacuum tube connector. 5. Remove the bolt and position the transmission fluid level indicator tube aside. 6. Disconnect the engine wiring harness retainers from the valve cover stud bolts. 7. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Remove the 11 fasteners and remove the RH valve cover. ^ Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. ^ Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent. Installation 1. Apply instant gel adhesive completely around the gasket groove in the valve cover and install the new valve cover gasket. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 1783 2. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply the silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head. 3. Position the valve cover and install the fasteners in the sequence shown to 10 Nm (89 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 1784 4. Attach the engine wiring harness retainers to the valve cover stud bolts. 5. Connect the vacuum tube connector. 6. Connect the PCV valve electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 1785 7. Position the transmission fluid level indicator tube and install the bolt. ^ Tighten to 10 Nm (89 lb-in). 8. Position the PCV tube and connect the quick connect couplings. 9. Install the suction accumulator. For additional information, refer to Heating and Air Conditioning. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Service and Repair Valve Guide: Service and Repair Valve Guide Inner Diameter 1. NOTE: Valve guides tend to wear in an hourglass pattern. The ball gauge can be inserted into the combustion chamber side of the valve guide if necessary. Use a ball gauge to determine the inner diameter of the valve guides in 2 directions at the top, middle and bottom of the valve guide. 2. Measure the ball gauge with a micrometer. 3. If the valve guide is not within specifications, install a new cylinder head assembly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Service and Repair Valve Seat: Service and Repair Valve Seat Inspection Valve and Seat Refacing Measurements NOTE: After grinding valves or valve seats, check valve clearance. 1. Check the valve head and seat. ^ Check valve angles. ^ Check margin width. ^ Be sure margin width is within specification. 2. Inspect for abnormalities on the valve face and seat. Install a new cylinder head assembly if abnormalities are found. Valve Seat Width 1. Measure the valve seat width. If necessary, grind the valve seat to specification. ^ Measure the intake valve seat width. ^ Measure the exhaust valve seat width. ^ Recheck the valve spring installed length after the seats have been ground, and shim the valve springs as necessary to achieve the correct installed spring length. Valve Seat Runout 1. Use a valve seat runout gauge to check valve seat runout. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Service and Repair > Page 1792 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures Valve Spring: Procedures Valve Spring Installed Length 1. Measure the installed length of each valve spring. Valve Spring Free Length 1. Measure the free length of each valve spring. Valve Spring Squareness 1. Measure the out-of-square on each valve spring. ^ Turn the valve spring and observe the space between the top of the valve spring and the square. Valve Spring Strength Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 1797 Special Tool(s) 1. Use the special tool to check the valve spring for correct strength at the specified valve spring length. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 1798 Valve Spring: Removal and Replacement Valve Springs Valve Train Components - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 1799 Valve Train Components - Exploded View (Part 2) Special Tool(s) Material Removal and Installation 1. If servicing the LH cylinder valve train components, remove the LH valve cover. 2. If servicing the RH cylinder valve train components, remove the RH valve cover. 3. Position the piston of the cylinder being serviced at the bottom of the stroke. 4. Install the special tool between the valve spring coils to protect the valve stem seal from damage. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 1800 5. CAUTION: The camshaft roller followers must be installed in their original locations. Record the camshaft roller follower locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. NOTE: The 3 rearmost camshaft roller followers on the RH side must use special tool 303-567 in the same manner as is shown in the illustration. Use the special tool to compress the valve springs and remove the camshaft roller follower. 6. NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation. Repeat the previous steps for each of the camshaft roller followers being serviced. 7. CAUTION: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. Remove the spark plugs. ^ To install, tighten to 18 Nm (13 lb-ft). 8. NOTE: Carry out the following steps for each cylinder requiring service. NOTE: Position the piston of the cylinder to be serviced at the bottom of the stroke. Use compressed air in the cylinder to hold both valves in position. 9. NOTE: The 3 rearmost followers on the RH side must use special tool 303-567 in the same manner as is shown in the illustration. NOTE: If a valve drops into the cylinder, the cylinder head must be removed. Using the special tools, compress the valve spring and remove the valve spring retainer keys. 10. Remove the valve spring retainers and the valve spring. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 1801 11. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection Valve: Testing and Inspection Valve Inspection 1. Inspect the following valve areas: 1 The end of the stem for grooves or scoring. 2 The valve face and the edge for pits, grooves or scores. 3 The valve head for signs of burning, erosion, warpage and cracking. 4 The valve margin for wear. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Valve Stem Diameter Valve: Service and Repair Valve Stem Diameter Valve Stem Diameter 1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Valve Stem Diameter > Page 1807 Valve: Service and Repair Valve Stem to Valve Guide Clearance Valve Stem to Valve Guide Clearance Special Tool(s) NOTE: The valve stem diameter must be within specifications before checking valve stem-to-valve guide clearance. 1. NOTE: If necessary, use a magnetic base. Install a Valve Guide Clearance Gauge on the valve stem and install a Dial Indicator Gauge with Holding Fixture. Lower the valve until the clearance gauge contacts the upper surface of the valve guide. 2. Move the clearance gauge toward the indicator and zero the indicator. Move the clearance gauge away from the indicator and note the reading. The reading will be DOUBLE the valve stem-to-valve guide clearance. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start Drive Belt: Customer Interest Engine - FEAD Idler Pulley Noise During Cold Start TSB 09-9-7 05/18/09 COLD START FEAD HOOT - WHISTLE NOISE FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150 LINCOLN: 2007-2008 Mark LT, Navigator MERCURY: 2007-2008 Mountaineer This article supersedes TSB 8-4-2 to remove the production build date. ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine; 2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer, Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive (FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED. 1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, Section 303-05. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 090907A 2007-2008 F-150/Mark LT 0.3 Hr. 4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Explorer/Mountaineer/ Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 1817 Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 Mustang 4.6L: 0.3 Hr. Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) DEALER CODING CONDITION BASIC PART NO. CODE 6C348 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start Drive Belt: All Technical Service Bulletins Engine - FEAD Idler Pulley Noise During Cold Start TSB 09-9-7 05/18/09 COLD START FEAD HOOT - WHISTLE NOISE FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150 LINCOLN: 2007-2008 Mark LT, Navigator MERCURY: 2007-2008 Mountaineer This article supersedes TSB 8-4-2 to remove the production build date. ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine; 2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer, Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive (FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED. 1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, Section 303-05. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 090907A 2007-2008 F-150/Mark LT 0.3 Hr. 4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Explorer/Mountaineer/ Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 1823 Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 Mustang 4.6L: 0.3 Hr. Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) DEALER CODING CONDITION BASIC PART NO. CODE 6C348 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1824 Drive Belt: Locations Accessory Drive 4.2 With A/C 4.2L Without A/C 4.6L (2V) And 5.4L (3V) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1825 Drive Belt: Diagrams Accessory Drive 4.2 With A/C 4.2L Without A/C 4.6L (2V) And 5.4L (3V) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1826 Drive Belt: Description and Operation Accessory Drive 4.2 With A/C 4.2L Without A/C 4.6L (2V) And 5.4L (3V) The accessory drive system: - has a single serpentine drive belt (6 ribs). - has 2 idler pulleys - 4.2L. - has 3 idler pulleys - 4.6L (2V) and 5.4L (3V). - has an automatic belt tensioner. - is not adjustable. The accessory drive system provides power to operate components which power other systems. These could include components such as the generator, power steering pump, and A/C compressor. Each of these components is equipped with a pulley which is driven by the accessory drive belt. The accessory drive belt is driven by the engine crankshaft pulley. One or more idler pulleys may be provided to facilitate belt routing and alignment. The Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1827 automatic belt tensioner maintains correct belt tension and compensates for component wear and changes in system load. System load changes can be caused by the A/C compressor clutch engaging and disengaging, or demand changes on other systems powered by the accessory drive belt. To maintain correct operation of this stem, it is critical that the correct length drive belt be installed. The pulleys must also be correctly aligned and kept clean. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview Inspection and Verification CAUTION: Under no circumstances should the accessory drive belt, tensioner or pulleys have any fluids or belt dressing applied to them as damage to the belt material and tensioner damping mechanism may occur. 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical damage. Visual Inspection Chart Visual Inspection Chart Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1830 Belt Tensioner With Belt Length Indicator 3. Check that the belt length indicator, if equipped, on the belt tensioner is in the acceptable belt installation and wear range. If the indicator is in the belt replacement range, either an incorrect belt is installed or the belt is worn beyond the service limit. Install a new belt as necessary. 4. Eliminate all other non-belt related noises that could cause belt misdiagnosis, such as A/C compressor engagement chirp, A/C slugging noise, power steering cavitations at low temperatures, variable camshaft timing (VCT) tick or generator whine. 5. If a concern is found, correct the condition before proceeding to the next step. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1831 V-Ribbed Serpentine Drive Belt With Cracks Across Ribs 6. Check the belt for cracks. Up to 15 cracks in a rib over a distance of 100 mm (4.0 inch) can be considered acceptable. If cracks exceed this standard, install a new belt. NOTE: Piling is an excessive buildup in the V-grooves of the belt. V-Ribbed Serpentine Belt With Piling 7. The condition of the V-ribbed drive belt should be compared against the illustration and appropriate action taken. 1 Small scattered deposits of rubber material. This is not a concern, therefore, installation of a new belt is not required. 2 Longer deposit areas building up to 50% of the rib height. This is not considered a durability concern, but it can result in excessive noise. If noise is apparent, install a new belt. 3 Heavy deposits building up along the grooves resulting in a possible noise and belt stability concern. If heavy deposits are apparent, install a new belt. V-Ribbed Serpentine Belt With Chunks of Rib Missing Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1832 8. There should be no chunks missing from the belt ribs. If the belt shows any evidence of this, install a new accessory drive belt. 9. If the concern is not visually evident, verify the symptom and GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1833 Drive Belt: Symptom Related Diagnostic Procedures Symptom Chart Symptom Chart (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1834 Symptom Chart (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1835 Drive Belt: Component Tests and General Diagnostics Component Tests Drive Belt - Noise/Flutter CAUTION: Under no circumstances should the accessory drive belt, tensioner or pulleys have any fluids or belt dressing applied to them as damage to the belt material and tensioner damping mechanism may occur. Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged or incorrectly aligned grooved pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley. Look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. Drive belt squeal may be an intermittent or constant noise that occurs when the drive belt slips on an accessory pulley under certain conditions. A short intermittent squeal may occur during engine start-up and shut down or during very rapid engine acceleration and decelerations, such as: ^ wide open throttle (WOT) 1-2 and 2-3 shifts or 2-3 and 3-4 back out shifts on automatic transmissions. ^ WOT 1-2 and 2-3 shifts and any combination of rapid downshifting on manual transmissions. These special short-term transient events are expected, and are due to the higher system inertias required to meet the electrical and cooling demands on today's vehicle systems. Constant or reoccurring drive belt squeal can occur: ^ if the A/C discharge pressure goes above specifications: - the A/C system is overcharged. - the A/C condenser core airflow is blocked. ^ if the A/C off equalized pressure (the common discharged and suction pressure that occurs after several minutes) exceeds specifications. ^ if any of the accessories or idler pulley(s) are damaged or have a worn or damaged bearing. All accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. ^ if there is evidence of fluid contamination on the accessory drive belt. When the drive belt has been exposed to fluid contamination during vehicle operation, such as leaks from the power steering system, A/C system or cooling system, clean all pulleys with soap and water, rinse with clean water and install a new accessory drive belt. If the drive belt has been exposed to fluids in a localized area during routine vehicle service, such as replacement of hoses or fluids, the drive belt and pulleys should be washed with soap and water immediately (prior to starting the engine), and rinsed with clean water. ^ if the accessory drive belt is too long. A drive belt that is too long will allow the accessory drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the accessory drive belt tensioner indicator is outside the normal installation wear range window, install a new accessory drive belt. NOTE: The accessory drive belt tensioner arm should rotate freely without binding. Install a new accessory drive belt tensioner if the drive belt tensioner is worn or damaged. Drive Belt - Incorrect Installation CAUTION: Incorrect accessory drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the pulleys. Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt tracks incorrectly, install a new accessory drive belt to avoid performance failure or loss of the drive belt. Incorrect Installation Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1836 Correct Installation With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the accessory drive belt rides beyond the edge of the pulleys, noise and premature wear will occur. Make sure the accessory drive belt rides correctly on the pulley. If an accessory drive belt tracking condition exists, proceed with the following: ^ Visually check the accessory drive belt tensioner for damage and wear, especially the mounting pad surface and arm alignment. If the accessory drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. If the tensioner arm is worn, the arm will be out of alignment. Either of these conditions will result in chirp and squeal noises. ^ With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the pulley forward faces) for excessive wobble. Install new components as necessary. ^ Check all accessories, mounting brackets and the accessory drive belt tensioner for any interference that would prevent the component from mounting correctly. Correct any interference condition and recheck the accessory drive belt tracking. ^ Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware to specification. Recheck the accessory drive belt tracking. Belt Tensioner - Mechanical The only mechanical check that needs to be made is a check for tensioner stick, grab or bind. 1. With the engine off, check routing of the accessory drive belt. Refer to the illustrations under Description and Operation in this section. 2. NOTE: The accessory drive belt tensioner spring is very strong and requires substantial force to release. Using a suitable, commercially available serpentine belt tensioner release tool, release the tension on the belt and detach the accessory drive belt from the tensioner. Carry out the following tests: ^ Using the release tool, move the tensioner from its relaxed position, through its full stroke and back to the relaxed position to make sure there is no stick, grab or bind, and to make sure that there is tension on the tensioner spring. ^ Rotate the tensioner pulley by hand and check for a binding, contaminated or seized condition. ^ Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination and repair any leaks. 3. If the accessory drive belt tensioner does not meet the criteria in the previous step, install a new tensioner. If the accessory drive belt tensioner meets the criteria in the previous step, proceed to testing the tensioner dynamically. Belt Tensioner - Dynamics The accessory drive belt tensioner can be checked dynamically as follows: 1. With the engine running, observe the accessory drive belt tensioner movement. The accessory drive tensioner should move (respond) when the A/C clutch cycles (if equipped), or when the engine is accelerated rapidly. If the accessory drive belt tensioner movement is excessive without A/C clutch cycling or engine acceleration, check belt rideout. Excessive belt rideout (uneven depth of grooves in the belt) can cause excessive accessory drive belt tensioner movement. Check rideout condition by installing a new belt. If excessive accessory drive belt tensioner movement still exists, install a new accessory drive belt tensioner. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 1837 Drive Belt: Service and Repair Accessory Drive Removal 1. Rotate the drive belt tensioner clockwise and remove the drive belt. Installation 1. To install, reverse the removal procedure. 4.2 With A/C 4.2L Without A/C 4.6L (2V) And 5.4L (3V) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner - 4.6L (2V) and 5.4L (3V) Front End Accessory Drive (FEAD) - Exploded View, 4.6L (2V) And 5.4L (3V) Removal and Installation 1. Remove the air cleaner intake pipe. For additional information, refer to Fuel Delivery and Air Induction. 2. Rotate the drive belt tensioner clockwise and detach the accessory drive belt from the drive belt tensioner. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Page 1841 3. Remove the 3 bolts and the drive belt tensioner. ^ To install, tighten to 25 Nm (18 lb-ft). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Body & Frame - Frame Replacement Matrix Engine Mount: Technical Service Bulletins Body & Frame - Frame Replacement Matrix TSB 07-25-13 12/24/07 FRAME REPLACEMENT MATRIX - SERVICE TIP FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 06-10-9 to update the vehicle model years. ISSUE Some Body Shops and Collision Repair Centers may find it necessary to replace frames on some 2004-2008 F-150 and 2006-2008 Mark LT vehicles. ACTION Use the Service Procedure and frame replacement matrix chart to properly repair the vehicle. SERVICE PROCEDURE Identify the current vehicle and frame level requiring replacement by inspecting the frame label. (Figure 1) At the top of the sticker will be 8L34-5005; the number in front of the L34 indicates model year of the frame. If necessary, work with Parts Central Order Processing (COPS) to make this determination. With COPS assistance, determine the service level frame that is available in service stock for the vehicle. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Body & Frame - Frame Replacement Matrix > Page 1846 NOTE LOCATE THE FRAME TAG LABEL ON THE FRAME RAIL. THIS LABEL IS LOCATED UNDER THE NUMBER 1 BODY MOUNT DIRECTLY UNDER THE 'A' PILLAR ON EITHER SIDE OF THE VEHICLE. HAVE THE 4 DIGIT SUFFIX FROM THE LABEL AND THE VIN WHEN CALLING PARTS. (Figure 2) Using the Service Frame Matrix (Figure 3), locate the vehicle being serviced and year of frame being replaced from the top of the matrix, and the available frame from the top of the matrix. The matrix is established with the assumption of 2008 MY frames being available to service earlier frames. The matrix will provide necessary parts to complete service frame replacement. NOTE SOME FRAMES FOR PAST MODEL YEARS MAY BE AVAILABLE THROUGH THE PARTS SYSTEM. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Body & Frame - Frame Replacement Matrix > Page 1847 NOTE FIGURE 4 IDENTIFIES LOCATION OF BULL NOSE. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Body & Frame - Frame Replacement Matrix > Page 1848 NOTE FIGURE 5 ENGINE MOUNT PART NUMBERS. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Body & Frame - Frame Replacement Matrix > Page 1849 Parts Block OTHER APPLICABLE ARTICLES: 06-03-04 WARRANTY STATUS: Information Only Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures Engine Mount: Procedures Powertrain/Drivetrain Mount Neutralizing NOTE: Refer to the appropriate information for special instructions on loosening and tightening mount fasteners. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 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 or damage to the mounts may occur. Start the vehicle and move it in forward 0.6-1.2 m (2-4 ft). Then move the vehicle in reverse the same distance. 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1852 Engine Mount: Removal and Replacement Engine Support Insulators Special Tool(s) Material Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1853 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1854 Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Disconnect the battery ground cable. For additional information, refer to Battery. 3. Remove the air cleaner and the air cleaner outlet pipe and resonator. For additional information, refer to Fuel Delivery and Air Induction. 4. Remove the generator. For additional information, refer to Alternator. 5. Remove the bolts and position the cooling fan shroud away from the radiator. 6. Remove the oil level indicator and the oil level indicator tube bolt. 7. Install the special tools. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1855 8. Remove the 4 exhaust manifold-to-catalytic converter nuts. 9. Remove the exhaust system support bracket bolts from the crossmember. 10. Remove the transmission mount nuts. Four wheel drive (4WD) vehicles 11. Remove the 4 nuts and lower the front stabilizer bar. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1856 RH engine support insulator 12. Remove the starter. For additional information, refer to Starting System. LH engine support insulator 13. If removing the LH engine support insulator in a four wheel drive (4WD) vehicle, index-mark the front driveshaft flange to the front axle pinion flange. 14. NOTE: Do not let the driveshaft hang unsupported. If removing the LH engine support insulator in a 4WD vehicle, disconnect and support the front driveshaft. ^ Remove the 4 bolts. ^ Support the front driveshaft. All vehicles 15. Remove the RH engine support insulator nuts and washer. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1857 16. Remove the LH engine support insulator bolt. 17. Using the special tools, raise the engine. RH engine support insulator 18. Remove the 3 RH engine support insulator bracket bolts. 19. Remove the 2 RH engine support insulator bracket-to-engine support insulator bolts. 20. Remove the RH engine support insulator bracket and the RH engine support insulator. LH engine support insulator 21. Remove the 3 LH engine support insulator bracket bolts. 22. Remove the oil level indicator tube from the cylinder block and position aside. ^ Discard the O-ring seal. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1858 23. Remove the 2 LH engine support insulator bracket-to-engine support insulator bolts. 24. Remove the LH engine support insulator bracket and the LH engine support insulator. Installation LH engine support insulator 1. NOTE: Clean the engine support insulator-to-bracket mating surfaces of any dirt or foreign material prior to installation. Install the LH engine support insulator bracket and the LH engine support insulator. 2. Install the 2 LH engine support insulator bracket-to-engine support insulator bolts. ^ Apply Threadlock(R) to the bolt threads prior to installation. ^ Tighten to 72 Nm (53 lb-ft). 3. Using a new O-ring seal, install the oil level indicator into the cylinder block. 4. NOTE: Clean the engine support insulator bracket-to-cylinder block mating surfaces of any dirt or foreign material prior to installation. Install the 3 LH engine support insulator bracket bolts. ^ Apply Threadlock(R) to the bolt threads prior to installation. ^ Tighten to 63 Nm (46 lb-ft). RH engine support insulator 5. NOTE: Clean the engine support insulator-to-bracket mating surfaces of any dirt or foreign material prior to installation. Install the RH engine support insulator bracket and the RH engine support insulator. 6. Install the 2 RH engine support insulator bracket-to-engine support insulator bolts. ^ Apply Threadlock(R) to the bolts threads prior to installation. ^ Tighten to 72 Nm (53 lb-ft). 7. NOTE: Clean the engine support insulator bracket-to-cylinder block mating surfaces of any dirt or foreign material prior to installation. Install the 3 RH engine support insulator bracket bolts. ^ Apply Threadlock(R) to the bolts threads prior to installation. ^ Tighten to 63 Nm (46 lb-ft). All vehicles Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1859 8. Lower the engine. 9. NOTE: Clean the engine support insulator-to-frame mating surfaces of any dirt or foreign material prior to installation. Apply Threadlock(R) to the threads and install the LH engine support insulator bolt. ^ Tighten to 350 Nm (258 lb-ft). 10. NOTE: Make sure the RH engine support insulator mating surfaces and the washer mating surface are free of foreign material and corrosion before installation. Install a new washer. Apply Threadlock(R) to the stud threads and install the RH engine support insulator washer and nuts. ^ Tighten to 250 Nm (184 lb-ft). LH engine support insulator 11. If installing the LH engine support insulator in a 4WD vehicle, align the front driveshaft flange-to-front axle pinion flange at the index mark and install the bolts. ^ Tighten to 111 Nm (82 lb-ft). RH engine support insulator 12. Install the starter. 4WD vehicles 13. Install the front stabilizer bar and the 4 nuts. ^ Tighten to 30 Nm (22 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1860 All vehicles 14. Install the transmission mount nuts. ^ Tighten to 103 Nm (76 lb-ft). 15. Install the exhaust system support bracket bolts from the crossmember. ^ Tighten to 40 Nm (30 lb-ft). 16. Install the 4 exhaust manifold-to-catalytic converter nuts. ^ Tighten to 40 Nm (30 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1861 17. Position the cooling fan shroud and install the bolts. ^ Tighten to 10 Nm (89 lb-in). 18. Position the oil level indicator tube and install the bolt and oil level indicator. ^ Tighten to 10 Nm (89 lb-in). 19. Install the generator. 20. Install the air cleaner and the air cleaner outlet pipe and resonator. 21. Connect the battery ground cable. For additional information, refer to Battery. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start Idler Pulley: Customer Interest Engine - FEAD Idler Pulley Noise During Cold Start TSB 09-9-7 05/18/09 COLD START FEAD HOOT - WHISTLE NOISE FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150 LINCOLN: 2007-2008 Mark LT, Navigator MERCURY: 2007-2008 Mountaineer This article supersedes TSB 8-4-2 to remove the production build date. ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine; 2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer, Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive (FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED. 1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, Section 303-05. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 090907A 2007-2008 F-150/Mark LT 0.3 Hr. 4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Explorer/Mountaineer/ Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 1870 Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 Mustang 4.6L: 0.3 Hr. Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) DEALER CODING CONDITION BASIC PART NO. CODE 6C348 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start Idler Pulley: All Technical Service Bulletins Engine - FEAD Idler Pulley Noise During Cold Start TSB 09-9-7 05/18/09 COLD START FEAD HOOT - WHISTLE NOISE FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150 LINCOLN: 2007-2008 Mark LT, Navigator MERCURY: 2007-2008 Mountaineer This article supersedes TSB 8-4-2 to remove the production build date. ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine; 2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer, Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive (FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED. 1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, Section 303-05. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 090907A 2007-2008 F-150/Mark LT 0.3 Hr. 4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 0.4 Hr. Explorer/Mountaineer/ Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 1876 Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) 090907A 2007-2008 Mustang 4.6L: 0.3 Hr. Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With 8678A, 8620F) DEALER CODING CONDITION BASIC PART NO. CODE 6C348 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Page 1877 Idler Pulley: Service and Repair Accessory Drive Belt Idler Pulley - 4.6L (2V) and 5.4L (3V) Front End Accessory Drive (FEAD) - Exploded View, 4.6L (2V) And 5.4L (3V) Removal and Installation Vehicles equipped with a 4.6L (2V) engine 1. Remove the engine cooling fan and shroud. For additional information, refer to Cooling System. Vehicles equipped with a 5.4L (3V) engine 2. Remove the air cleaner intake pipe. For additional information, refer to Fuel Delivery and Air Induction. All vehicles 3. Rotate the drive belt tensioner clockwise and detach the drive belt from the idler pulley. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Page 1878 4. Remove the bolt and the idler pulley. ^ To install, tighten to 25 Nm (18 lb-ft). 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure At 2,000 rpm (Engine At Normal Operating Temperature) ................................................................................ 275-517 kPa (40-75 psi) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1883 Engine Oil Pressure: Testing and Inspection Oil Pressure Test 1. Disconnect and remove the oil pressure sensor from the engine. 2. Connect the Oil Pressure Gauge to the oil pressure sender oil galley port. 3. Run the engine until normal operating temperature is reached. 4. Run the engine at the specified rpm and record the gauge reading. 5. The oil pressure should be within specifications. 6. If the pressure is not within specification, check the following possible sources: ^ Insufficient oil ^ Oil leakage ^ Worn or damaged oil pump ^ Oil pump screen cover and tube ^ Excessive main bearing clearance ^ Excessive connecting rod bearing clearance Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Material Removal and Installation 1. Remove the LH exhaust manifold. 2. Remove the oil level indicator tube bolt. ^ To install, tighten to 10 Nm (89 lb-in). 3. Remove the oil level indicator tube and discard the O-ring seal. 4. NOTE: Install a new O-ring seal. Lubricate the O-ring seal with clean engine oil prior to installation. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Capacity 4.2L Engine ......................................................................................................................................... ............................................................ 5.68L (6.0 qt)* 4.6L Engine ......................................................................................................................................... .............................................................. 5.7L (6.0 qt)* * With filter. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1891 Engine Oil: Fluid Type Specifications Engine Oil U.S. ........................................................................................................................................ Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil Canada ................................................................................................................................................... Motorcraft SAE 5W-20 Super Premium Motor Oil Ford Part Number: ................................................................................................................................ XO-5W20-QSP (US), CXO-5W20LSP12 (Canada) Ford Specification: .................................................................................................................................................. WSS-M2C930-A and API Certification NOTE: Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only meet the requirements of Ford specification WSS-M2C930-A and the API Certification mark. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair Oil Filter Adapter: Service and Repair Oil Filter Adapter Material Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 1895 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Drain the coolant. For additional information, refer to Cooling System. 3. Remove and discard the engine oil filter. ^ To install, lubricate the oil filter gasket with clean engine oil. 4. Release the lower radiator hose clamp and position the lower radiator hose aside. 5. Release the coolant reservoir hose clamp and position the coolant reservoir hose aside. 6. Disconnect the engine oil pressure (EOP) switch electrical connector. 7. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces. Remove the 4 oil filter adapter bolts, the oil filter adapter and discard the gasket. Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces. ^ To install, tighten to 25 Nm (18 lb-ft). 8. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts First pass ............................................................................................................................................. ..................................................... 2 Nm (18 lb-in). Second pass ........................................................ ..................................................................................................................................... 20 Nm (15 lb-ft). Final pass ................................................................................................................................... ................................................ Tighten an additional 60° Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1899 Oil Pan: Service and Repair Oil Pan Skid Plate and Fasteners Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1900 Oil Pan, Oil Pump and Oil Pump Screen and Pickup Tube Material Removal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1901 All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Drain the engine oil. 3. If equipped, remove the 4 skid plate bolts and the skid plate. 4. Remove the bolts and the crossmember. Four wheel drive (4WD) vehicles 5. Position a suitable hydraulic jack under the front axle. Securely strap the jack to the axle. 6. NOTE: Rotate the steering column so the pinch bolt for the steering column coupling allows clearance for the isolator bolt. Remove the upper front axle carrier mounting bushing bolt. 7. Remove the axle shaft housing carrier bushing bolt. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1902 8. Remove the lower front axle carrier mounting bushing bolt. 9. Partially lower the front axle assembly. All vehicles 10. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces. Remove the 16 oil pan bolts, the oil pan and discard the oil pan gasket. Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces. Installation All vehicles 1. NOTE: If the oil pan is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply the silicone gasket and sealant at the engine front cover-to-cylinder block mating surface. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1903 2. NOTE: If the oil pan is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant in the locations shown. 3. Position the new oil pan gasket and the oil pan and loosely install the 16 bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1904 4. Tighten the bolts in 3 stages in the sequence shown. ^ Stage 1: Tighten to 2 Nm (18 lb-in). ^ Stage 2: Tighten to 20 Nm (15 lb-ft). ^ Stage 3: Tighten an additional 60 degrees. 4WD vehicles 5. Position the front axle. 6. NOTE: Rotate the steering column so the pinch bolt for the steering column coupling allows clearance for the isolator bolt. Install the upper front axle carrier mounting bushing bolt. ^ Tighten to 90 Nm (66 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1905 7. Install the axle shaft housing carrier bushing nut and bolt. ^ Tighten to 90 Nm (66 lb-ft). 8. Install the lower front axle carrier mounting bushing bolt. ^ Tighten to 90 Nm (66 lb-ft). All vehicles 9. Install the crossmember and the 4 bolts. ^ Tighten to 115 Nm (85 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1906 10. If equipped, install the skid plate and the 4 bolts. ^ Tighten to 25 Nm (18 lb-ft). 11. Install the engine oil pan drain plug and fill the engine with clean engine oil. ^ Tighten to 14 Nm (10 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 1910 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 1911 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 1912 C103 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 1913 Oil Pressure Sender: Service and Repair Engine Oil Pressure (EOP) Switch Engine Oil Pressure (EOP) Switch Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the engine oil pressure (EOP) switch. ^ To install, tighten to 18 Nm (13 lb-ft). 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair Oil Pick Up/Strainer: Service and Repair Oil Pump Screen and Pickup Tube Skid Plate and Fasteners Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Page 1917 Oil Pan, Oil Pump and Oil Pump Screen and Pickup Tube Material Removal 1. Remove the oil pan. 2. Remove the 3 bolts and the oil pump screen and pickup tube. ^ Discard the O-ring seal. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Page 1918 Installation 1. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage. NOTE: Install a new O-ring and lubricate with clean engine oil. Install the oil pump screen and pickup tube and the 3 bolts. 1 Tighten to 25 Nm (18 lb-ft). 2 Tighten to 10 Nm (89 lb-in). 2. Install the oil pan. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure At 2,000 rpm (Engine At Normal Operating Temperature) ................................................................................ 275-517 kPa (40-75 psi) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1923 Engine Oil Pressure: Testing and Inspection Oil Pressure Test 1. Disconnect and remove the oil pressure sensor from the engine. 2. Connect the Oil Pressure Gauge to the oil pressure sender oil galley port. 3. Run the engine until normal operating temperature is reached. 4. Run the engine at the specified rpm and record the gauge reading. 5. The oil pressure should be within specifications. 6. If the pressure is not within specification, check the following possible sources: ^ Insufficient oil ^ Oil leakage ^ Worn or damaged oil pump ^ Oil pump screen cover and tube ^ Excessive main bearing clearance ^ Excessive connecting rod bearing clearance Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Description and Operation Oil Temperature Sensor/Switch: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Intake Manifold Bolts ........................................................................................................................... ................................................... 10 Nm (89 lb-in). Throttle Body (TB) Bolts First pass ............................................................................................................................................. ..................................................... 9 Nm (80 lb-in). Final pass ............................................................ ....................................................................................................... Tighten an additional 90° (1/4 turn) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement Intake Manifold: Removal and Replacement Intake Manifold Material EGR System Module Tube, PCV Tube, Electrical and Vacuum Connections (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement > Page 1932 EGR System Module Tube, PCV Tube, Electrical and Vacuum Connections (Part 2) Intake Manifold and Gaskets (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement > Page 1933 Intake Manifold and Gaskets (Part 2) Removal WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Disconnect the fuel hose spring lock coupling. Release the fuel system pressure. For additional information, refer to Fuel Delivery and Air Induction. 2. Disconnect the battery ground cable. For additional information, refer to Battery. 3. Drain the cooling system. For additional information, refer to Cooling System. 4. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction. 5. Remove the ignition coils. For additional information, refer to Ignition System. 6. Remove the generator. For additional information, refer to Alternator. 7. Remove the EGR system module tube. 8. Disconnect the EGR system module electrical connector. 9. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to Fuel Delivery and Air Induction. 10. Disconnect the electronic throttle control electrical connector. 11. Disconnect the fuel rail pressure and temperature sensor electrical connector. 12. Disconnect the fuel rail pressure and temperature sensor vacuum connector. 13. Disconnect the 8 fuel injector electrical connectors. 14. Disconnect the vacuum and coolant hose and plug the coolant hose. 15. Disconnect the brake booster vacuum hose and the evaporative emissions (EVAP) hose quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement > Page 1934 16. Disconnect the upper radiator coolant hose and position aside. 17. Disconnect the heater coolant hose and position aside. 18. Remove the 3 power steering reservoir support bracket bolts and the power steering reservoir support bracket. 19. Disconnect the vacuum hose. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement > Page 1935 20. Remove the 2 thermostat housing bolts and the thermostat housing and discard the O-ring seal. 21. Remove the thermostat. 22. Remove the 9 intake manifold bolts. 23. Remove the intake manifold and discard the RH and LH intake manifold gaskets. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Clean the mating surfaces of the cylinder head and the intake manifold with metal surface prep and silicone gasket remover. Follow the directions on the packaging. 2. Install the intake manifold in the following sequence. 1 Position the new intake manifold gaskets. 2 Position the intake manifold. 3 Loosely install the 9 intake manifold bolts. 3. Tighten the intake manifold bolts in the sequence shown. ^ Tighten to 10 Nm (89 lb-in). 4. Install the thermostat. 5. Install the thermostat housing and a new thermostat housing O-ring seal. 6. Install the 2 thermostat housing bolts. ^ Tighten to 25 Nm (18 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement > Page 1936 7. Connect the fuel hose spring lock coupling. Release the fuel system pressure. 8. Connect the vacuum hose. 9. Install the power steering reservoir support bracket and the 3 bolts. ^ Tighten the 2 bracket-to-power steering reservoir bolts to 17 Nm (13 lb-ft). ^ Tighten the power steering reservoir bracket-to-thermostat housing bolt to 11 Nm (8 lb-ft). 10. Connect the heater coolant hose. 11. Connect the upper radiator coolant hose. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement > Page 1937 12. Connect the electronic throttle control electrical connector. 13. Connect the fuel rail pressure and temperature sensor electrical connector. 14. Connect the fuel rail pressure and temperature sensor vacuum connector. 15. Connect the 8 fuel injector electrical connectors. 16. Connect the vacuum and coolant hose. 17. Connect the brake booster vacuum hose and the EVAP hose quick connect coupling. 18. Install the EGR system module tube. ^ Tighten to 40 Nm (30 lb-ft). 19. Connect the EGR system module electrical connector. 20. Position the PCV tube and connect the quick connect couplings. For additional information, refer to Fuel Delivery and Air Induction. 21. Install the ignition coils. 22. Install the generator. 23. Install the air cleaner outlet pipe. 24. Connect the battery ground cable. For additional information, refer to Battery. 25. Fill and bleed the engine cooling system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement > Page 1938 Intake Manifold: Overhaul Intake Manifold Assembly Material Fuel Rail and Fuel Injectors Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement > Page 1939 EGR System Module and Throttle Body (TB) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement > Page 1940 Coolant Bypass Tube and Intake Manifold Disassembly WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. 1. Remove the 4 fuel rail stud bolts. 2. NOTE: When removing the fuel rail, leave the fuel injectors in the intake manifold. This will make removal of the fuel rail easier. Separate the fuel rail from the fuel injectors and remove the fuel rail. 3. Remove fuel injectors. ^ Discard the O-ring seals. 4. Disconnect and remove the PCV coolant hose. 5. Remove the 4 throttle body (TB) bolts and the TB. ^ Discard the TB gasket. 6. Remove the EGR system module bolts and the EGR system module. ^ Discard the EGR system module gasket. 7. Remove the 6 coolant bypass tube bolts. 8. Remove the coolant bypass tube. ^ Discard the gaskets. Assembly 1. Position new coolant bypass tube gaskets, the coolant bypass tube and install the 6 bolts. ^ Tighten to 10 Nm (89 lb-in). 2. Install a new EGR gasket (with the raised gasket surface facing the throttle body spacer) and the EGR system module and the bolts. ^ Tighten to 25 Nm (18 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Replacement > Page 1941 3. Install a new TB gasket and the TB and tighten the 4 TB bolts in 2 stages. ^ Stage 1: Tighten to 9 Nm (80 lb-in). ^ Stage 2: Tighten an additional 90 degrees (1/4 turn). 4. Install the PCV coolant hose. 5. NOTE: Install new fuel injector O-ring seals on the fuel injectors. NOTE: Lubricate the new fuel injector O-ring seals with clean engine oil prior to installation. ^ Using new O-ring seals, install the fuel injectors. 6. Install the fuel rail and the 4 fuel rail stud bolts. ^ Tighten to 10 Nm (89 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Seal Crankshaft Rear Seal Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 1947 Special Tool(s) Material Removal 1. Remove the transmission. 2. Remove the 6 flexplate bolts and the flexplate. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 1948 3. Remove the engine rear cover plate. 4. Using the special tools, remove and discard the crankshaft oil slinger. 5. Using the special tools, remove and discard the crankshaft rear seal. Installation 1. NOTE: Lubricate the crankshaft rear seal with clean engine oil prior to installation. Using the special tools, install a new crankshaft rear seal. 2. NOTE: Lubricate the crankshaft oil slinger with clean engine oil prior to installation. Using the special tools, install a new crankshaft oil slinger. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 1949 3. Install the engine rear cover plate. 4. Install the flexplate and the 6 bolts. Tighten the bolts in 2 stages in the sequence shown. ^ Stage 1: Tighten to 20 Nm (15 lb-ft). ^ Stage 2: Tighten to 80 Nm (59 lb-ft). 5. Install the transmission. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 1950 Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Seal With Retainer Plate Crankshaft Rear Seal with Retainer Plate Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 1951 Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 1952 Material Removal 1. Remove the transmission. 2. Remove the 6 flexplate bolts and the flexplate. 3. Remove the engine rear cover plate. 4. Remove the oil pan. 5. Using the special tools, remove and discard the crankshaft oil slinger. 6. Using the special tools, remove and discard the crankshaft rear seal. 7. Remove the 6 crankshaft rear seal retainer plate bolts and the crankshaft rear seal retainer plate. 8. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 1953 Clean and inspect the mating surface. Installation 1. NOTE: The rear crankshaft seal retainer plate does not have a sealant groove. Gasket maker must be applied to the rear crankshaft seal retainer plate mating surface on the engine block. Apply a bead of gasket maker to the rear crankshaft seal retainer plate mating surface on the engine block. 2. Position the crankshaft seal retainer plate and tighten the bolts in the sequence shown. ^ Tighten to 10 Nm (89 lb-in). 3. NOTE: Lubricate the crankshaft rear seal with clean engine oil prior to installation. Using the special tools, install a new crankshaft rear seal. 4. NOTE: Lubricate the crankshaft oil slinger with clean engine oil prior to installation. Using the special tools, install a new crankshaft oil slinger. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 1954 5. Install the oil pan. 6. Install the engine rear cover plate. 7. Install the flexplate and the 6 bolts. Tighten the bolts in 2 stages in the sequence shown. ^ Stage 1: Tighten to 20 Nm (15 lb-ft). ^ Stage 2: Tighten to 80 Nm (59 lb-ft). 8. Install the transmission. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Seal Special Tool(s) Material Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1958 Removal 1. Remove the crankshaft pulley. 2. Using the special tool, remove and discard the crankshaft front seal. Installation 1. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1959 2. Using the special tools, install a new crankshaft front seal. 3. Install the crankshaft pulley. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 Valve Seals Valve Train Components - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 1963 Valve Train Components - Exploded View (Part 2) Special Tool(s) Material Removal 1. Remove the valve springs for each valve seal being serviced. 2. Remove and discard the valve stem seal. Installation 1. NOTE: The 3 rearmost valve seals on the RH side must use special tool 303-567 in the same manner as is shown in the illustration. NOTE: Lubricate the valve seal with clean engine oil prior to installation. Using the special tools, install the new valve stem seal. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 1964 2. Install the valve springs. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1969 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1970 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1971 C103 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1972 Oil Pressure Sender: Service and Repair Engine Oil Pressure (EOP) Switch Engine Oil Pressure (EOP) Switch Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the engine oil pressure (EOP) switch. ^ To install, tighten to 18 Nm (13 lb-ft). 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Description and Operation Oil Temperature Sensor/Switch: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Pulley Bolt CAUTION: This bolt is torque-to-yield and cannot be reused. Failure to follow these instructions may result in engine damage. First pass ............................................................................................................................................. .................................................... 90 Nm (66 lb-ft). Second pass ........................................................ ................................................................................................................................ Loosen one full turn Third pass ..................................................................................................................................... .......................................................... 50 Nm (37 lb-ft). Final pass ..................................................................................................................... Tighten an additional 90° without exceeding 200 Nm (148 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Timing Chain Tensioner Bolts ............................................................................................................. .................................................... 25 Nm (18 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine Front Cover Front Fasteners ...................................................................................................................................................... 25 Nm (18 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1986 Engine Front Cover Lower Fasteners First pass ............................................................................................................................................. .................................................... 20 Nm (15 lb-ft). Final pass ............................................................ ....................................................................................................................... Tighten an additional 60° Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1987 Timing Cover: Service and Repair Engine Front Cover Special Tool(s) (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1988 Special Tool(s) (Part 2) Material Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1989 Accessory Drive Belt, Idler Pullies and Crankshaft Pulley Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1990 Power Steering Pump, Coolant Pump Pulley and Electrical Connections (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1991 Power Steering Pump, Coolant Pump Pulley and Electrical Connections (Part 2) Engine Front Cover and Gaskets (Part 1) Engine Front Cover and Gaskets (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1992 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Drain the engine oil. 3. Remove the cooling fan. For additional information, refer to Cooling System. 4. Remove the RH valve cover. 5. Remove the LH valve cover. 6. Rotate the tensioner clockwise and remove the drive belt. 7. CAUTION: This bolt is torque-to-yield and cannot be reused. Failure to follow these instructions may result in engine damage. Using the special tool, remove the bolt and washer and discard the bolt. 8. Using the special tool, remove the crankshaft pulley. 9. Using the special tool, remove and discard the crankshaft front seal. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1993 10. Remove the 4 coolant pump pulley bolts and the coolant pump pulley. 11. Remove the 3 bolts and the 3 accessory drive belt idler pulleys. 12. Using the special tool, remove the power steering pump pulley. 13. Disconnect the power steering pressure tube. ^ Drain the power steering fluid into a suitable container. 14. Remove the nut and position aside the power steering pressure tube. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1994 15. Remove the bolts and position the power steering pump assembly aside. 16. Disconnect the camshaft position (CMP) sensor electrical connector. 17. Remove the (CMP) sensor bolt and the CMP sensor. 18. Remove the nut and position the LH radio interference capacitor aside. 19. Remove the nut and the upper radiator hose bracket. 20. Remove the nut and position the RH radio interference capacitor aside. 21. Disconnect the crankshaft position (CKP) sensor electrical connector. 22. Remove the 4 oil pan bolts. 23. Remove the nut and the A/C manifold and tube assembly support bracket. 24. If equipped, remove the nut and the transmission cooler tube support bracket. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1995 25. Remove the bolts and the studs. 26. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Remove the engine front cover from the front cover-to-cylinder block dowel. ^ Remove the engine front cover gaskets. ^ Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. ^ Inspect the mating surfaces. 27. Remove the CKP sensor bolt and the CKP sensor. Installation 1. Install the CKP sensor and the CKP sensor bolt. ^ Tighten to 10 Nm (89 lb-in). 2. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1996 NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown. 3. Install the engine front cover with the engine front cover gasket on the front cover-to-cylinder block dowel and loosely install the bolts. 4. Tighten the engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1997 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1998 5. Loosely install the bolts, then tighten the bolts in 2 stages, in the sequence shown. ^ Stage 1: Tighten to 20 Nm (15 lb-ft). ^ Stage 2: Tighten an additional 60 degrees. 6. If equipped, install the transmission cooler tube support bracket and nut. ^ Tighten to 10 Nm (89 lb-in). 7. Install the A/C manifold and tube assembly support bracket and nut. ^ Tighten to 10 Nm (89 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1999 8. Connect the CKP sensor electrical connector. 9. Position the RH radio interference capacitor and install the nut. ^ Tighten to 25 Nm (18 lb-ft). 10. Position the upper radiator hose bracket and install the nut. ^ Tighten to 10 Nm (89 lb-in). 11. Position the LH radio interference capacitor and install the nut. ^ Tighten to 25 Nm (18 lb-ft). 12. Install the CMP sensor and the bolt. ^ Tighten to 10 Nm (89 lb-in). 13. Connect the CMP sensor electrical connector. 14. Position the power steering pump and install the bolts. ^ Tighten to 25 Nm (18 lb-ft). 15. Using the special tool, install a new O-ring seal on the pressure line fitting. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2000 16. Connect the power steering pressure tube. ^ Tighten to 65 Nm (48 lb-ft). 17. Position the power steering pressure tube support bracket and install the nut. ^ Tighten to 12 Nm (9 lb-ft). 18. NOTE: If the pulley has been removed and installed twice, install a new power steering pump pulley. Using the special tool, install the power steering pump pulley. ^ Inspect the pulley for paint marks in the web area near the hub. If there are 2 paint marks, install a new pulley. If there is one paint mark or none at all, use a pencil to mark the web area of the pulley near the hub. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2001 19. Install the 3 accessory drive belt idler pulleys and the 3 bolts. ^ Tighten to 25 Nm (18 lb-ft). 20. Install the coolant pump pulley and the 4 bolts. ^ Tighten to 25 Nm (18 lb-ft). 21. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil. 22. Using the special tools, install a new crankshaft front seal. 23. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2002 24. Using the special tool, install the crankshaft pulley. 25. Using a new crankshaft pulley bolt, install the crankshaft pulley bolt and washer. Using the special tool to hold the crankshaft pulley, tighten the bolt in 4 stages: ^ Stage 1: Tighten to 90 Nm (66 lb-ft). ^ Stage 2: Loosen one full turn. ^ Stage 3: Tighten to 50 Nm (37 lb-ft). ^ Stage 4: Tighten an additional 90 degrees without exceeding 200 Nm (148 lb-ft). 26. Rotate the tensioner clockwise and install the drive belt. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2003 27. Install the LH valve cover. 28. Install the RH valve cover. 29. Install the cooling fan. 30. Fill the engine with clean engine oil. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 C1451 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 2009 C1452 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Page 2010 Variable Valve Timing Actuator: Description and Operation VARIABLE CAMSHAFT TIMING (VCT) SYSTEM Overview The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are 4 types of VCT systems. - Exhaust phase shifting (EPS) system - the exhaust cam is the active cam being retarded. - Intake phase shifting (IPS) system - the intake cam is the active cam being advanced. - Dual equal phase shifting (DEPS) system - both intake and exhaust cams are phase shifted and equally advanced or retarded. - Dual independent phase shifting (DIPS) system - where both the intake and exhaust cams are shifted independently. All systems have 4 operational modes: idle, part throttle, wide open throttle (WOT), and default mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM) determines the phase angle based on air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque. In addition, some VCT system applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used. Variable Camshaft Timing (VCT) System VCT System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A crankshaft position (CKP) sensor provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, engine oil temperature (EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part and wide open throttle, the camshaft position is determined by engine RPM, load and throttle position. The VCT system does not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle. The PCM calculates and determines the desired camshaft position. It continually updates the VCT solenoid duty cycle until the desired position is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Page 2011 disables the VCT and places the camshaft in a default position if a concern is detected. A related DTC is also set when the concern is detected. 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Item....................................................................................................................................................... ..............................................................Specification Fuel Pressure Engine running..................................................................................................................................... ..............................................193-310 kPa (28-45 psi) Key ON, engine OFF (KOEO)......................... ..................................................................................................................................240-310 kPa (35-45 psi) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2016 Fuel Pressure: Testing and Inspection FUEL SYSTEM PRESSURE TEST Special Tool(s) Special Tool(s) WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. 1. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. 2. NOTE: 5.4L shown, 4.6L and 4.2L similar. Install the special tools in line between the fuel supply tube and fuel rail. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2017 3. NOTE: The electrical connector was disconnected during fuel system pressure release. Connect the electrical connector. 4. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 5. Test the fuel system pressure to make sure it is within the specified range. 6. NOTE: - 5.4L shown, 4.6L and 4.2L similar. - Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Upon completion of the fuel system pressure test, open the drain valve on the special tool and relieve the fuel system pressure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Typical Diagnostic Reference Value Measured/PID Values 665 RPM .......................................................................................................... ..................................................................................................... Hot Idle Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair AIR CLEANER ELEMENT Exploded View Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. Detach the electrical connector retainer. 2. Loosen the clamp and disconnect the air cleaner outlet pipe from the air cleaner cover. - To install, tighten to 4 Nm (35 lb-in). 3. Open the clamp and detach the air cleaner cover from the air cleaner tray. 4. Remove the air cleaner element. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE Special Tool(s) Special Tool(s) 1. NOTE: The splash shield is located on the LH frame rail under the driver side door. Disconnect the splash shield and position aside. 2. Disconnect the electrical connector. 3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition switch to the OFF position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 2029 6. When fuel system service is complete, connect the electrical connector. 7. Reposition the splash shield and install a new pushpin. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Install the scan tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON. Select the appropriate vehicle and engine qualifier. Clear all DTCs and carry out a PCM reset. 10. Start the vehicle and check the fuel system for leaks. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing order........................................................................................................................................... ...........................................................1-3-7-2-6-5-4-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications Item....................................................................................................................................................... ..............................................................Specification Base timing........................................................................................................................................... ............................10° before top dead center (BTDC) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions TSB 08-7-6 04/14/08 SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008 Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part List. ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and 2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07. ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and extract broken spark plugs. SERVICE PROCEDURE The engine build date can be read on the left hand cam cover information sticker. To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before removal is attempted. CAUTION DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS COULD BE DAMAGED. Spark Plug Removal Procedure 1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and surrounding valve cover area with compressed air. 2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4 teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark plug back and forth at this point. NOTE COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL. CAUTION EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE. CAUTION DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST ONLY BE REMOVED WITH HAND TOOLS. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2040 3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the back and forth turning as needed until turning effort is reduced, and remove the spark plugs. NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. (Figure 1) Separated/Broken Spark Plug Removal If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of three modes. Refer to the appropriate removal procedure as required. a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2) b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head. (Figure 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2041 c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground shield. (Figure 4) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2042 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2043 Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the cylinder head. (Figure 6) NOTE THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD. IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL. 1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be removed. (Figure 7) 2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and protect the combustion chamber from contamination. (Figure 7) 3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4 reduced diameter threads on the tip end). a. Coat the end of the tap with general purpose grease. (Figure 8) b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K) is provided with service tool 303-1203 update to connect the tap to a 3/8" socket Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2044 drive. CAUTION DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED. 4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9) a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out. b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to prevent thread stripping. c. Install the nylon washer and jack nut until finger tight. d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool assembly. NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. Mode 2 Procedure: 1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug well and allow 15 minutes of soak time. 2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking care not to fracture the porcelain. 3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder head. Mode 3 Procedure: CAUTION DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2045 Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground electrode shield. (FIGURE 10) Porcelain Removal - Preparation CAUTION THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21 °C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF ADHESIVE. CAUTION DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR BONDING. 1. Remove any remaining electrode material from broken porcelain with long nose reach pliers. 2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the straw nozzle supplied with the brake cleaner can. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2046 3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2047 4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14) NOTE PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN. 5. Insert the completed assembly into the spark plug well and fully engage the pin into the porcelain. (Figure 15) 6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to flood the porcelain and pin. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2048 7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take care making sure the pin does not disengage the porcelain. (Figure 16). 8. Repeat Steps 6 and 7. 9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry compressed air. NOTE CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN. 10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed. 11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry compressed air. Porcelain Removal - Bonding Process CAUTION USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER HEAD. NOTE WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES. 1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator. (Figure 17) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2049 2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18). 3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2. 4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent starts to cure. 5. Reassemble a dry and clean collet and pin assembly. 6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of Loctite® 638TMare being used if it drips off the pin. 7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin. 8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain with a twisting motion to spread the bonding agent. 9. Add additional Loctite® 638TM, repeating Steps 6-8. 10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19). CAUTION A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE EXTRACTION IS ATTEMPTED. 11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C). 12. Repeat the bonding process for remaining cylinders as needed. Porcelain Removal - Extraction 1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded rod. 2. Install the washer and jack nut until finger tight against the tool pilot bushing. CAUTION ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL. 3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is free of the ground electrode. 4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder head. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2050 NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7) Porcelain Removal - Pin Slipped Out In the unlikely event that the pin does not remove the broken porcelain, this process can be repeated. Key elements to success are: ^ Clean and dry porcelain ^ Sufficient Loctite® 638TM Retaining Compound spread uniformly ^ Loctite(R) 638(TM) cure time and temperature ^ Preventing the threaded rod from rotating while removing the porcelain Replacement Supplies Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT080706 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 12405 01 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > General Specifications Spark Plug: Specifications General Specifications Item....................................................................................................................................................... ..............................................................Specification Spark plug gap..................................................................................................................................... ....................................1.32-1.42 mm (0.052-0.056 in) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > General Specifications > Page 2053 Torque Specifications Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2054 Spark Plug: Application and ID Item....................................................................................................................................................... ..............................................................Specification Spark plug............................................................................................................................................ ...................................................................AGSF-32N Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2055 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Install a new spark plug. 2. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. ^ Install new spark plugs. 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2056 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a Heli-Coil(R) insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by white or light gray spots and with a bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Install new spark plugs. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2057 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2058 Spark Plug: Service and Repair SPARK PLUGS Exploded View Removal and Installation 1. Remove the ignition coil-on-plug. 2. CAUTION: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. - If an original spark plug is used, make sure it is installed in the same cylinder from which it was taken. New spark plugs can be used in any cylinder. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2059 Remove the spark plugs. To install, tighten to 15 Nm (11 lb-ft). 3. Inspect the spark plugs. Install new spark plugs as necessary. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2063 Compression Check: Testing and Inspection Compression Test - Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of 5 compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2064 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75% of the highest reading. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance This engine is equipped with hydraulic lash adjusters. No adjustment is required. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Drive Pulley, Water Pump > Component Information > Technical Service Bulletins > Customer Interest for Drive Pulley: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures Drive Pulley: Customer Interest A/C - Compressor Shuts OFF in High Temperatures TSB 07-24-7 12/10/07 A/C COMPRESSOR SHUTOFF - HIGH AMBIENT TEMPERATURES - VEHICLE STATIONARY IN GEAR FORD: 2007-2008 F-150, F-150 LINCOLN: 2007-2008 Mark LT ISSUE Some 2007-2008 Mark LT and F-150 vehicles equipped with 5.4L or 4.6L engine only, may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C), when the vehicle is stationary for periods longer than 15 minutes, with the transmission in gear. Idling in gear and extreme ambient temperatures may cause the vehicle control systems to disable A/C compressor operation. ACTION Follow the Service Procedure steps to replace the A/C compressor pulley and coolant pump pulley. SERVICE PROCEDURE NOTE THIS TSB IS INTENDED TO RESTORE A/C COMPRESSOR OPERATION IN EXTREME HIGH AMBIENT TEMPERATURES WHEN THE TRANSMISSION IS PLACED IN THE PARK POSITION. DO NOT ATTEMPT TO ADDRESS CUSTOMER CONCERNS OF GENERAL A/C TEMPERATURE OUTPUT PERFORMANCE WITH THIS TSB. THIS TSB WILL NOT IMPROVE A/C SYSTEM DUCT TEMPERATURE OUTPUT PERFORMANCE. NOTE DURING EXTREME HIGH AMBIENT TEMPERATURES WHEN IDLING STATIONARY FOR EXTENDED PERIODS OF TIME IN GEAR, IT IS RECOMMENDED TO OPERATE THE A/C IN THE MAX POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, AND PUT THE TRANSMISSION INTO THE PARK POSITION TO CONTINUE TO RECEIVE COOL AIR FROM THE A/C SYSTEM. 1. Replace the A/C compressor pulley. Follow Workshop Manual (WSM), Section 412-01 for removal and installation details. 2. Replace the coolant pump pulley. Follow WSM, Section 303-03 for removal and installation details. 3. Drain approximately 1 quart of coolant from the cooling system into a clean container which will permit reuse of coolant in the vehicle. Refer to WSM, Section 303-03. 4. Replace the clamp on the heater core feed hose, near the right hand front of engine, at the water pump outlet pipe connection point. 5. Refill the cooling system. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072407A 2007-2008 F-150 4X2, 1.7 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X2. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Drive Pulley, Water Pump > Component Information > Technical Service Bulletins > Customer Interest for Drive Pulley: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures > Page 2077 8509A,8620F, 8616A, 18472A). 072407B 2007-2008 F-150 4X4, 1.9 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X4. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, 8509A,8620F, 8616A, 18472A). DEALER CODING CONDITION BASIC PART NO. CODE 8A616 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Drive Pulley, Water Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Pulley: > 07-24-7 > Dec > 07 > A/C Compressor Shuts OFF in High Temperatures Drive Pulley: All Technical Service Bulletins A/C - Compressor Shuts OFF in High Temperatures TSB 07-24-7 12/10/07 A/C COMPRESSOR SHUTOFF - HIGH AMBIENT TEMPERATURES - VEHICLE STATIONARY IN GEAR FORD: 2007-2008 F-150, F-150 LINCOLN: 2007-2008 Mark LT ISSUE Some 2007-2008 Mark LT and F-150 vehicles equipped with 5.4L or 4.6L engine only, may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C), when the vehicle is stationary for periods longer than 15 minutes, with the transmission in gear. Idling in gear and extreme ambient temperatures may cause the vehicle control systems to disable A/C compressor operation. ACTION Follow the Service Procedure steps to replace the A/C compressor pulley and coolant pump pulley. SERVICE PROCEDURE NOTE THIS TSB IS INTENDED TO RESTORE A/C COMPRESSOR OPERATION IN EXTREME HIGH AMBIENT TEMPERATURES WHEN THE TRANSMISSION IS PLACED IN THE PARK POSITION. DO NOT ATTEMPT TO ADDRESS CUSTOMER CONCERNS OF GENERAL A/C TEMPERATURE OUTPUT PERFORMANCE WITH THIS TSB. THIS TSB WILL NOT IMPROVE A/C SYSTEM DUCT TEMPERATURE OUTPUT PERFORMANCE. NOTE DURING EXTREME HIGH AMBIENT TEMPERATURES WHEN IDLING STATIONARY FOR EXTENDED PERIODS OF TIME IN GEAR, IT IS RECOMMENDED TO OPERATE THE A/C IN THE MAX POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, AND PUT THE TRANSMISSION INTO THE PARK POSITION TO CONTINUE TO RECEIVE COOL AIR FROM THE A/C SYSTEM. 1. Replace the A/C compressor pulley. Follow Workshop Manual (WSM), Section 412-01 for removal and installation details. 2. Replace the coolant pump pulley. Follow WSM, Section 303-03 for removal and installation details. 3. Drain approximately 1 quart of coolant from the cooling system into a clean container which will permit reuse of coolant in the vehicle. Refer to WSM, Section 303-03. 4. Replace the clamp on the heater core feed hose, near the right hand front of engine, at the water pump outlet pipe connection point. 5. Refill the cooling system. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072407A 2007-2008 F-150 4X2, 1.7 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X2. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Drive Pulley, Water Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Pulley: > 07-24-7 > Dec > 07 > A/C Compressor Shuts OFF in High Temperatures > Page 2083 8509A,8620F, 8616A, 18472A). 072407B 2007-2008 F-150 4X4, 1.9 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X4. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, 8509A,8620F, 8616A, 18472A). DEALER CODING CONDITION BASIC PART NO. CODE 8A616 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine Coolant 4.2 ........................................................................................................................................................ .................................................... 17.6 quarts (16.7L) 4.6 ................................................................... ......................................................................................................................................... 20.5 quarts (19.4L) 5.4 ........................................................................................................................................... ................................................................. 20.9 quarts (19.8L) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2089 Coolant: Fluid Type Specifications ENGINE COOLANT Motorcraft Premium Gold Engine Coolant with bittering agent (yellow-colored) Ford Part Number: .. .............................................................................................................................................................. .................................. VC-7-B Ford Specification: ............................................................................... ................................................................................................. WSS-M97B51-A1 NOTE: Add the coolant type originally equipped in your vehicle. RECYCLED ENGINE COOLANT Ford Motor Company does NOT recommend the use of recycled engine coolant in vehicles originally equipped with Motorcraft Premium Gold Engine Coolant since a Ford-approved recycling process is not yet available. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair Coolant Reservoir: Service and Repair Degas Bottle Degas Bottle Removal and Installation 1. WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury. Release the pressure in the cooling system by slowly turning the pressure relief cap one half turn counterclockwise. When the pressure is released, remove the pressure relief cap. 2. Using hose clamp pliers, clamp the coolant return hose. 3. Using a suitable suction device, siphon the coolant from the degas bottle. 4. Release the clamp and disconnect the degas bottle upper hose. 5. Release the clamp and disconnect the coolant return hose. 6. Remove the bolts and the degas bottle. ^ To install, tighten to 9 Nm (80 lb-in). 7. To install, reverse the removal procedure. 8. Fill the degas bottle. Refer to Cooling System Draining, Filling and Bleeding for the recommended coolant mixture and fill level. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2098 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2099 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2100 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2101 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2102 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2103 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2104 Radiator Cooling Fan Motor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2105 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2106 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2107 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2108 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2109 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2110 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2111 Radiator Cooling Fan Motor: Description and Operation FAN CONTROL The PCM monitors certain parameters (such as engine coolant temperature, vehicle speed, A/C on/off status, A/C pressure) to determine engine cooling fan needs. For variable speed electric fan(s): Edge/MKX, Taurus/Taurus X/Sable, Fusion/Milan/MKZ, Crown Victoria/Grand Marquis, Town Car: FCV Duty Cycle Output From PCM (Negative Duty Cycle) The PCM controls the fan speed and operation using a duty cycle output on the fan control variable (FCV) circuit. The fan controller (located at or integral to the engine cooling fan assembly) receives the FCV command and operates the cooling fan at the speed requested (by varying the power applied to the fan motor). For relay controlled fans: 2.0L Focus (With A/C): PCM FC Output State For Cooling Fan Speeds 2.3L Escape: PCM FC Output State For Cooling Fan Speeds The PCM controls the fan operation through the fan control (FC) (single speed fan applications), low fan control (LFC), medium fan control (MFC), and high fan control (HFC) outputs. Some applications will have the xFC circuit wired-to 2 separate-relays. For 3-speed fans, although the PCM output circuits are called low, medium, and high fan control (FC), cooling fan speed is controlled by a combination of these outputs. Refer to the table. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Speed Sensor > Component Information > Description and Operation Radiator Cooling Fan Speed Sensor: Description and Operation FAN SPEED SENSOR (FSS) Cooling Fan Clutch With FSS The FSS is a Hall-effect sensor that measures the cooling fan clutch speed by generating a waveform with a frequency proportional to the fan speed. If the cooling fan clutch is moving at a relatively low speed, the sensor produces a signal with a low frequency. As the cooling fan clutch speed increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the FSS as a feedback for closed loop control of the cooling fan clutch. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair Fan Blade: Service and Repair Cooling Fan - Blade, Clutch and Shroud Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair > Page 2118 Fan Clutch Wiring Harness and Air Cleaner Tube Bracket Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair > Page 2119 Cooling Fan Blade, Clutch and Shroud All vehicles 1. Remove the pin-type retainers and the radiator appearance cover. Vehicles equipped with a 4.2L or 4.6L (2V) engine 2. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction. Vehicles equipped with a 4.6L (2V) or 5.4L (3V) engine 3. Detach the battery cable harness retainer from the radiator shroud. 4. Disconnect the electronic cooling fan clutch electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair > Page 2120 5. Remove the nut and detach the electronic cooling fan clutch wiring harness from the stud bolt. ^ To install, tighten to 13 Nm (10 lb-ft). Vehicles equipped with a 5.4L (3V) engine 6. Remove the air cleaner intake pipe. For additional information, refer to Fuel Delivery and Air Induction. 7. Remove the bolts and the air cleaner intake pipe support bracket. ^ To install, tighten to 10 Nm (89 lb-in). Vehicles equipped with a 4.2L engine 8. Using the special tools, remove the cooling fan assembly and position it in the fan shroud. ^ To install, tighten to 55 Nm (41 lb-ft). Vehicles equipped with a 4.6L (2V) or 5.4L (3V) engine 9. CAUTION: Do not side load the cooling fan clutch coil or the cooling fan clutch may be damaged. Using the special tools, remove the cooling fan assembly and position it in the fan shroud. ^ To install, tighten to 55 Nm (41 lb-ft). All vehicles 10. Remove the bolts and the cooling fan shroud and cooling fan. ^ To install, tighten to 6 Nm (53 lb-in). 11. If servicing the cooling fan or cooling fan clutch, refer to Cooling Fan and Cooling Fan Clutch. 12. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams C1158 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams > Page 2124 Fan Clutch: Description and Operation COOLING FAN CLUTCH Cooling Fan Clutch With Fan Speed Sensor (FSS) The cooling fan clutch is an electrically actuated viscous clutch that consists of 3 main elements: - a working chamber - a reservoir chamber - a cooling fan clutch actuator valve and a fan speed sensor (FSS) The cooling fan clutch actuator valve controls the fluid flow from the reservoir into the working chamber. Once viscous fluid is in the working chamber, shearing of the fluid results in fan rotation. The cooling fan clutch actuator valve is activated with a pulse width modulated (PWM) output signal from the PCM. By opening and closing the fluid port valve, the PCM can control the cooling fan clutch speed. The cooling fan clutch speed is measured by a Hall-effect sensor and is monitored by the PCM during closed loop operation. The PCM optimizes fan speed based on engine coolant temperature (ECT), engine oil temperature (EOT), transmission fluid temperature (TFT), intake air temperature (IAT), or air conditioning requirements. When an increased demand for fan speed is requested for vehicle cooling, the PCM monitors the fan speed through the Hall-effect sensor. If a fan speed increase is required, the PCM outputs the PWM signal to the fluid port, providing the required fan speed increase. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams > Page 2125 Fan Clutch: Service and Repair Cooling Fan - Blade, Clutch and Shroud Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams > Page 2126 Fan Clutch Wiring Harness and Air Cleaner Tube Bracket Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams > Page 2127 Cooling Fan Blade, Clutch and Shroud All vehicles 1. Remove the pin-type retainers and the radiator appearance cover. Vehicles equipped with a 4.2L or 4.6L (2V) engine 2. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction. Vehicles equipped with a 4.6L (2V) or 5.4L (3V) engine 3. Detach the battery cable harness retainer from the radiator shroud. 4. Disconnect the electronic cooling fan clutch electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams > Page 2128 5. Remove the nut and detach the electronic cooling fan clutch wiring harness from the stud bolt. ^ To install, tighten to 13 Nm (10 lb-ft). Vehicles equipped with a 5.4L (3V) engine 6. Remove the air cleaner intake pipe. For additional information, refer to Fuel Delivery and Air Induction. 7. Remove the bolts and the air cleaner intake pipe support bracket. ^ To install, tighten to 10 Nm (89 lb-in). Vehicles equipped with a 4.2L engine 8. Using the special tools, remove the cooling fan assembly and position it in the fan shroud. ^ To install, tighten to 55 Nm (41 lb-ft). Vehicles equipped with a 4.6L (2V) or 5.4L (3V) engine 9. CAUTION: Do not side load the cooling fan clutch coil or the cooling fan clutch may be damaged. Using the special tools, remove the cooling fan assembly and position it in the fan shroud. ^ To install, tighten to 55 Nm (41 lb-ft). All vehicles 10. Remove the bolts and the cooling fan shroud and cooling fan. ^ To install, tighten to 6 Nm (53 lb-in). 11. If servicing the cooling fan or cooling fan clutch, refer to Cooling Fan and Cooling Fan Clutch. 12. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams > Page 2129 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 F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2134 C107 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2135 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2136 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Remove the generator. 2. Disconnect the cylinder head temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. - Apply anti-seize to the threads of the CHT sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair Fan Shroud: Service and Repair Cooling Fan - Blade, Clutch and Shroud Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 2140 Fan Clutch Wiring Harness and Air Cleaner Tube Bracket Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 2141 Cooling Fan Blade, Clutch and Shroud All vehicles 1. Remove the pin-type retainers and the radiator appearance cover. Vehicles equipped with a 4.2L or 4.6L (2V) engine 2. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction. Vehicles equipped with a 4.6L (2V) or 5.4L (3V) engine 3. Detach the battery cable harness retainer from the radiator shroud. 4. Disconnect the electronic cooling fan clutch electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 2142 5. Remove the nut and detach the electronic cooling fan clutch wiring harness from the stud bolt. ^ To install, tighten to 13 Nm (10 lb-ft). Vehicles equipped with a 5.4L (3V) engine 6. Remove the air cleaner intake pipe. For additional information, refer to Fuel Delivery and Air Induction. 7. Remove the bolts and the air cleaner intake pipe support bracket. ^ To install, tighten to 10 Nm (89 lb-in). Vehicles equipped with a 4.2L engine 8. Using the special tools, remove the cooling fan assembly and position it in the fan shroud. ^ To install, tighten to 55 Nm (41 lb-ft). Vehicles equipped with a 4.6L (2V) or 5.4L (3V) engine 9. CAUTION: Do not side load the cooling fan clutch coil or the cooling fan clutch may be damaged. Using the special tools, remove the cooling fan assembly and position it in the fan shroud. ^ To install, tighten to 55 Nm (41 lb-ft). All vehicles 10. Remove the bolts and the cooling fan shroud and cooling fan. ^ To install, tighten to 6 Nm (53 lb-in). 11. If servicing the cooling fan or cooling fan clutch, refer to Cooling Fan and Cooling Fan Clutch. 12. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Testing and Inspection Heater Core: Testing and Inspection HEATER CORE 1. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores were good and did not require replacement. If a heater core leak is suspected, the heater core must be tested by carrying out the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly as follows: Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. 2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Check the integrity of the heater water hose clamps. Heater Core - Plugged 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core inlet and outlet hose to see if they are hot. If the inlet hose is not hot: the thermostat is not working correctly. If the outlet hose is not hot: the heater core may have an air pocket. - the heater core may be restricted or plugged. Heater Core - Pressure Test Use the Radiator/Heater Core Pressure Tester to carry out the pressure test. 1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. Clamp off the heater hoses. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 in) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and Adapter BT-7422-A from the Radiator/Heater Core Pressure Tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Radiator/Heater Core Pressure Tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of 3 minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the bench test. Heater Core - Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 in) test heater water hoses with plug and adapter to the core tubes. Then connect the Radiator/Heater Core Pressure Tester to the adapter. 4. Apply 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new heater core. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Testing and Inspection > Page 2146 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Testing and Inspection > Page 2147 Heater Core: Service and Repair HEATER CORE Removal and Installation NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 1. Remove the heater core and evaporator core housing. 2. Remove the dash panel seal from the heater core tubes. 3. Position the temperature blend door actuator aside in the following sequence. 1 Remove the 3 temperature blend door actuator screws. 2 Position the temperature blend door actuator aside. 4. Remove the heater core cover in the following sequence. 1 Remove the 4 heater core cover screws. 2 Remove the heater core cover. 5. Remove the heater core. 6. NOTE: The heater core seal must be correctly installed to prevent airflow from bypassing the heater core. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures Heater Hose: Customer Interest A/C - Compressor Shuts OFF in High Temperatures TSB 07-24-7 12/10/07 A/C COMPRESSOR SHUTOFF - HIGH AMBIENT TEMPERATURES - VEHICLE STATIONARY IN GEAR FORD: 2007-2008 F-150, F-150 LINCOLN: 2007-2008 Mark LT ISSUE Some 2007-2008 Mark LT and F-150 vehicles equipped with 5.4L or 4.6L engine only, may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C), when the vehicle is stationary for periods longer than 15 minutes, with the transmission in gear. Idling in gear and extreme ambient temperatures may cause the vehicle control systems to disable A/C compressor operation. ACTION Follow the Service Procedure steps to replace the A/C compressor pulley and coolant pump pulley. SERVICE PROCEDURE NOTE THIS TSB IS INTENDED TO RESTORE A/C COMPRESSOR OPERATION IN EXTREME HIGH AMBIENT TEMPERATURES WHEN THE TRANSMISSION IS PLACED IN THE PARK POSITION. DO NOT ATTEMPT TO ADDRESS CUSTOMER CONCERNS OF GENERAL A/C TEMPERATURE OUTPUT PERFORMANCE WITH THIS TSB. THIS TSB WILL NOT IMPROVE A/C SYSTEM DUCT TEMPERATURE OUTPUT PERFORMANCE. NOTE DURING EXTREME HIGH AMBIENT TEMPERATURES WHEN IDLING STATIONARY FOR EXTENDED PERIODS OF TIME IN GEAR, IT IS RECOMMENDED TO OPERATE THE A/C IN THE MAX POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, AND PUT THE TRANSMISSION INTO THE PARK POSITION TO CONTINUE TO RECEIVE COOL AIR FROM THE A/C SYSTEM. 1. Replace the A/C compressor pulley. Follow Workshop Manual (WSM), Section 412-01 for removal and installation details. 2. Replace the coolant pump pulley. Follow WSM, Section 303-03 for removal and installation details. 3. Drain approximately 1 quart of coolant from the cooling system into a clean container which will permit reuse of coolant in the vehicle. Refer to WSM, Section 303-03. 4. Replace the clamp on the heater core feed hose, near the right hand front of engine, at the water pump outlet pipe connection point. 5. Refill the cooling system. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072407A 2007-2008 F-150 4X2, 1.7 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X2. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures > Page 2156 8509A,8620F, 8616A, 18472A). 072407B 2007-2008 F-150 4X4, 1.9 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X4. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, 8509A,8620F, 8616A, 18472A). DEALER CODING CONDITION BASIC PART NO. CODE 8A616 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures Heater Hose: All Technical Service Bulletins A/C - Compressor Shuts OFF in High Temperatures TSB 07-24-7 12/10/07 A/C COMPRESSOR SHUTOFF - HIGH AMBIENT TEMPERATURES - VEHICLE STATIONARY IN GEAR FORD: 2007-2008 F-150, F-150 LINCOLN: 2007-2008 Mark LT ISSUE Some 2007-2008 Mark LT and F-150 vehicles equipped with 5.4L or 4.6L engine only, may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C), when the vehicle is stationary for periods longer than 15 minutes, with the transmission in gear. Idling in gear and extreme ambient temperatures may cause the vehicle control systems to disable A/C compressor operation. ACTION Follow the Service Procedure steps to replace the A/C compressor pulley and coolant pump pulley. SERVICE PROCEDURE NOTE THIS TSB IS INTENDED TO RESTORE A/C COMPRESSOR OPERATION IN EXTREME HIGH AMBIENT TEMPERATURES WHEN THE TRANSMISSION IS PLACED IN THE PARK POSITION. DO NOT ATTEMPT TO ADDRESS CUSTOMER CONCERNS OF GENERAL A/C TEMPERATURE OUTPUT PERFORMANCE WITH THIS TSB. THIS TSB WILL NOT IMPROVE A/C SYSTEM DUCT TEMPERATURE OUTPUT PERFORMANCE. NOTE DURING EXTREME HIGH AMBIENT TEMPERATURES WHEN IDLING STATIONARY FOR EXTENDED PERIODS OF TIME IN GEAR, IT IS RECOMMENDED TO OPERATE THE A/C IN THE MAX POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, AND PUT THE TRANSMISSION INTO THE PARK POSITION TO CONTINUE TO RECEIVE COOL AIR FROM THE A/C SYSTEM. 1. Replace the A/C compressor pulley. Follow Workshop Manual (WSM), Section 412-01 for removal and installation details. 2. Replace the coolant pump pulley. Follow WSM, Section 303-03 for removal and installation details. 3. Drain approximately 1 quart of coolant from the cooling system into a clean container which will permit reuse of coolant in the vehicle. Refer to WSM, Section 303-03. 4. Replace the clamp on the heater core feed hose, near the right hand front of engine, at the water pump outlet pipe connection point. 5. Refill the cooling system. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072407A 2007-2008 F-150 4X2, 1.7 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X2. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures > Page 2162 8509A,8620F, 8616A, 18472A). 072407B 2007-2008 F-150 4X4, 1.9 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X4. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, 8509A,8620F, 8616A, 18472A). DEALER CODING CONDITION BASIC PART NO. CODE 8A616 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Radiator Cooling Fan Speed Sensor > Component Information > Description and Operation Radiator Cooling Fan Speed Sensor: Description and Operation FAN SPEED SENSOR (FSS) Cooling Fan Clutch With FSS The FSS is a Hall-effect sensor that measures the cooling fan clutch speed by generating a waveform with a frequency proportional to the fan speed. If the cooling fan clutch is moving at a relatively low speed, the sensor produces a signal with a low frequency. As the cooling fan clutch speed increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the FSS as a feedback for closed loop control of the cooling fan clutch. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2171 C107 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2172 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2173 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Remove the generator. 2. Disconnect the cylinder head temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. - Apply anti-seize to the threads of the CHT sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Opening Temperatures Starts to open ...................................................................................................................................... ..................................... 86.7-90.6° C (188-195° F) Fully open ........................................................... ................................................................................................................... 97.8-101.7° C (208-215° F) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2177 Thermostat: Service and Repair Thermostat - 4.6L (2V) Thermostat - 4.6L (2V) Removal and Installation 1. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding. 2. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air Induction. 3. If servicing the thermostat housing, release the upper radiator hose clamp and disconnect the radiator hose from the thermostat housing. 4. Remove the power steering upper bracket-to-thermostat housing bolt. ^ To install, tighten to 11 Nm (8 lb-ft). 5. Remove the power steering upper bracket-to-intermediate bracket bolts and the power steering upper bracket. ^ To install, tighten to 17 Nm (13 lb-ft). 6. Remove the bolts and position the thermostat housing aside. ^ To install, tighten to 25 Nm (18 lb-ft). 7. Remove the thermostat and the O-ring seal. ^ Discard the O-ring seal. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2178 8. To install, reverse the removal procedure. ^ Install a new O-ring seal and lubricate with clean engine coolant. 9. Fill and bleed the cooling system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Drive Pulley, Water Pump > Component Information > Technical Service Bulletins > Customer Interest for Drive Pulley: > 07-24-7 > Dec > 07 > A/C Compressor Shuts OFF in High Temperatures Drive Pulley: Customer Interest A/C - Compressor Shuts OFF in High Temperatures TSB 07-24-7 12/10/07 A/C COMPRESSOR SHUTOFF - HIGH AMBIENT TEMPERATURES - VEHICLE STATIONARY IN GEAR FORD: 2007-2008 F-150, F-150 LINCOLN: 2007-2008 Mark LT ISSUE Some 2007-2008 Mark LT and F-150 vehicles equipped with 5.4L or 4.6L engine only, may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C), when the vehicle is stationary for periods longer than 15 minutes, with the transmission in gear. Idling in gear and extreme ambient temperatures may cause the vehicle control systems to disable A/C compressor operation. ACTION Follow the Service Procedure steps to replace the A/C compressor pulley and coolant pump pulley. SERVICE PROCEDURE NOTE THIS TSB IS INTENDED TO RESTORE A/C COMPRESSOR OPERATION IN EXTREME HIGH AMBIENT TEMPERATURES WHEN THE TRANSMISSION IS PLACED IN THE PARK POSITION. DO NOT ATTEMPT TO ADDRESS CUSTOMER CONCERNS OF GENERAL A/C TEMPERATURE OUTPUT PERFORMANCE WITH THIS TSB. THIS TSB WILL NOT IMPROVE A/C SYSTEM DUCT TEMPERATURE OUTPUT PERFORMANCE. NOTE DURING EXTREME HIGH AMBIENT TEMPERATURES WHEN IDLING STATIONARY FOR EXTENDED PERIODS OF TIME IN GEAR, IT IS RECOMMENDED TO OPERATE THE A/C IN THE MAX POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, AND PUT THE TRANSMISSION INTO THE PARK POSITION TO CONTINUE TO RECEIVE COOL AIR FROM THE A/C SYSTEM. 1. Replace the A/C compressor pulley. Follow Workshop Manual (WSM), Section 412-01 for removal and installation details. 2. Replace the coolant pump pulley. Follow WSM, Section 303-03 for removal and installation details. 3. Drain approximately 1 quart of coolant from the cooling system into a clean container which will permit reuse of coolant in the vehicle. Refer to WSM, Section 303-03. 4. Replace the clamp on the heater core feed hose, near the right hand front of engine, at the water pump outlet pipe connection point. 5. Refill the cooling system. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072407A 2007-2008 F-150 4X2, 1.7 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X2. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Drive Pulley, Water Pump > Component Information > Technical Service Bulletins > Customer Interest for Drive Pulley: > 07-24-7 > Dec > 07 > A/C Compressor Shuts OFF in High Temperatures > Page 2188 8509A,8620F, 8616A, 18472A). 072407B 2007-2008 F-150 4X4, 1.9 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X4. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, 8509A,8620F, 8616A, 18472A). DEALER CODING CONDITION BASIC PART NO. CODE 8A616 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Drive Pulley, Water Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Pulley: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures Drive Pulley: All Technical Service Bulletins A/C - Compressor Shuts OFF in High Temperatures TSB 07-24-7 12/10/07 A/C COMPRESSOR SHUTOFF - HIGH AMBIENT TEMPERATURES - VEHICLE STATIONARY IN GEAR FORD: 2007-2008 F-150, F-150 LINCOLN: 2007-2008 Mark LT ISSUE Some 2007-2008 Mark LT and F-150 vehicles equipped with 5.4L or 4.6L engine only, may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C), when the vehicle is stationary for periods longer than 15 minutes, with the transmission in gear. Idling in gear and extreme ambient temperatures may cause the vehicle control systems to disable A/C compressor operation. ACTION Follow the Service Procedure steps to replace the A/C compressor pulley and coolant pump pulley. SERVICE PROCEDURE NOTE THIS TSB IS INTENDED TO RESTORE A/C COMPRESSOR OPERATION IN EXTREME HIGH AMBIENT TEMPERATURES WHEN THE TRANSMISSION IS PLACED IN THE PARK POSITION. DO NOT ATTEMPT TO ADDRESS CUSTOMER CONCERNS OF GENERAL A/C TEMPERATURE OUTPUT PERFORMANCE WITH THIS TSB. THIS TSB WILL NOT IMPROVE A/C SYSTEM DUCT TEMPERATURE OUTPUT PERFORMANCE. NOTE DURING EXTREME HIGH AMBIENT TEMPERATURES WHEN IDLING STATIONARY FOR EXTENDED PERIODS OF TIME IN GEAR, IT IS RECOMMENDED TO OPERATE THE A/C IN THE MAX POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, AND PUT THE TRANSMISSION INTO THE PARK POSITION TO CONTINUE TO RECEIVE COOL AIR FROM THE A/C SYSTEM. 1. Replace the A/C compressor pulley. Follow Workshop Manual (WSM), Section 412-01 for removal and installation details. 2. Replace the coolant pump pulley. Follow WSM, Section 303-03 for removal and installation details. 3. Drain approximately 1 quart of coolant from the cooling system into a clean container which will permit reuse of coolant in the vehicle. Refer to WSM, Section 303-03. 4. Replace the clamp on the heater core feed hose, near the right hand front of engine, at the water pump outlet pipe connection point. 5. Refill the cooling system. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072407A 2007-2008 F-150 4X2, 1.7 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X2. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Drive Pulley, Water Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Pulley: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures > Page 2194 8509A,8620F, 8616A, 18472A). 072407B 2007-2008 F-150 4X4, 1.9 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X4. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, 8509A,8620F, 8616A, 18472A). DEALER CODING CONDITION BASIC PART NO. CODE 8A616 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation CATALYST AND EXHAUST SYSTEMS Overview V-Engines In-Line Engines The catalytic converter and exhaust systems work together to control the release of harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of nitrogen (N), carbon dioxide (CO2) and water vapor (H2O). However, it also contains carbon monoxide (CO), oxides of nitrogen (NOx), hydrogen (H), and various unburned hydrocarbons (HCs). The major air pollutants of CO, NOx,and HCs, and their emission into the atmosphere must be controlled. The exhaust system generally consists of an exhaust manifold, front exhaust pipe, front heated oxygen sensor (HO2S), rear exhaust pipe, catalyst HO2S, a muffler, and an exhaust tailpipe. The catalytic converter is typically installed between the front and rear exhaust pipes. On some vehicle applications, more than one catalyst is used between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the on board diagnostic (OBD) system strategy in the powertrain control module (PCM). For information on the OBD catalyst monitor, refer to the description for the Catalyst Efficiency Monitor. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes/Catalyst Efficiency Monitor For most vehicles, only 2 HO2Ss are used in an exhaust stream. The front sensors (HO2S11/HO2S21) before the catalyst are used for primary fuel control while the ones after the catalyst (HO2S12/HO2S22) are used to monitor catalyst efficiency. However, some partial zero emission vehicles (PZEV) use 3 HO2Ss for each engine bank. The stream 1 sensors (HO2S11/HO2S21) located before the catalyst are used for primary fuel control, the stream 2 sensors (HO2S12/HO2S22) are used to monitor the light-off catalyst, and the stream 3 sensors (HO2S13/HO2S23) located after the catalyst are used for long term fuel trim control to optimize catalyst efficiency (fore aft oxygen sensor control). Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst also enables a chemical reaction to occur at a lower temperature. The concentration of exhaust gas products released to the atmosphere must be controlled. The catalytic Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2199 converter assists in this task. It contains a catalyst in the form of a specially treated ceramic honeycomb structure saturated with catalytically active precious metals. As the exhaust gases come in contact with the catalyst, they are changed into mostly harmless products. The catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components so they are used up as much as possible. Light Off Catalyst As the catalyst heats up, converter efficiency rises rapidly. The point at which conversion efficiency exceeds 50% is called catalyst light off. For most catalysts this point occurs at 246°C to 302°C (475°F to 575°F). A fast light catalyst is a 3-way catalyst (TWC) that is located as close to the exhaust manifold as possible. Because the light off catalyst is located close to the exhaust manifold it lights off faster and reduces emissions more quickly than the catalyst located under the body. Once the catalyst lights off, the catalyst quickly reaches the maximum conversion efficiency for that catalyst. Three-Way Catalyst (TWC) Conversion Efficiency TWC Conversion Efficiency Chart A TWC requires a stoichiometric fuel ratio, 14.7 pounds of air to 1 pound of fuel (14.7:1), for high conversion efficiency. In order to achieve these high efficiencies, the air/fuel ratio must be tightly controlled with a narrow window of stoichiometry. Deviations outside of this window greatly decrease the conversion efficiency. For example a rich mixture decreases the HC and CO conversion efficiency while a lean mixture decreases the NOx conversion efficiency. Exhaust System Typical Bank 1 Catalyst 2 HO2S Configuration Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2200 Typical Bank 1 Catalyst 3 HO2S Configuration The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. A HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of CO, unburned HCs, and NOx in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter past another HO2S mounted in the rear exhaust pipe and then on into the muffler. Finally, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. On some PZEV, there is a total of 3 HO2S in the exhaust stream. One near the exhaust manifold (stream 1), one in the middle of the light-off catalyst (stream 2), and the third (stream 3) is mounted after the light-off catalyst. Underbody Catalyst The underbody catalyst is located after the light off catalyst. The underbody catalyst may be in line with the light off catalyst, or the underbody catalyst may be common to 2 light off catalysts, forming a Y pipe configuration. For an exact configuration of the catalyst and exhaust system for a specific vehicle, refer to Exhaust System for the exhaust system-exploded view. Three-Way Catalytic (TWC) Converter The TWC converter contains either platinum (Pt) and rhodium (Rh) or palladium (Pd) and rhodium (Rh). The TWC converter catalyzes the oxidation reactions of unburned HCs and CO and the reduction reaction of NOx. The 3-way conversion can be best accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Exhaust Manifold Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on the engine configuration and number of cylinders. Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. Heated Oxygen Sensor (HO2S) The HO2Ss provide the PCM with information related to the oxygen content of the exhaust gas. Muffler Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The muffler reduces the level of noise produced by the engine, and also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair Exhaust Crossover Pipe: Service and Repair Exhaust Y-Pipe - Dual Catalytic Converter Exhaust System - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair > Page 2204 Exhaust System - Exploded View (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair > Page 2205 Harley Davidson (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair > Page 2206 Harley Davidson (Part 2) Material Removal All engines CAUTION: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger bracket during vehicle operation. NOTE: The exhaust Y-pipe-dual catalytic converter is a 2-piece assembly. The RH and LH converters can be serviced separately as needed. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. If equipped, remove the skid plate. 4.6L and 5.4L engines 3. Disconnect the LH heated oxygen sensor (HO2S) electrical connector. All engines 4. Disconnect the catalyst monitor sensors electrical connectors. 5. Loosen the exhaust Y-pipe--dual catalytic converter-to-exhaust intermediate pipe coupling. Slide the coupling back onto the exhaust intermediate Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair > Page 2207 pipe. 6. Loosen the RH catalytic converter-to-LH catalytic converter clamp. 7. NOTE: 4.6L and 5.4L shown, 4.2L similar. Remove the nuts on the LH catalytic converter-to-exhaust manifold joint. ^ Discard the nuts. 8. NOTE: 4.6L and 5.4L shown, 4.2L similar. Remove the nuts on the RH catalytic converter-to-exhaust manifold joint. ^ Discard the nuts. 4.6L and 5.4L engines 9. Let the RH catalytic convert drop down slightly and then disconnect the RH HO2S electrical connector. All engines 10. NOTE: LH side shown, RH similar. Remove the heat shield bolts from the transmission crossmember. 4.6L and 5.4L engines 11. NOTE: A special tool is available for use in removing the HO2S. An open-end wrench can be used for ease of removal. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to assist in removal. Remove the 2 HO2S. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair > Page 2208 All engines 12. NOTE: A special tool is available for use in removing the catalyst monitor sensors. An open-end wrench can be used for ease of removal. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to assist in removal. Remove the 2 catalyst monitor sensors. 13. Remove the exhaust Y-pipe-dual catalytic converter hanger bracket and isolator bolts. 14. Remove the RH catalytic converter. 15. Remove the LH catalytic converter. Installation NOTE: Clean the mating surfaces of the manifold outlet flare and the catalytic converter inlet flare. All engines 1. Position the RH catalytic converter. 4.6L and 5.4L engines 2. NOTE: Make sure to apply anti-seize lubricant to the threads of the sensors before installation. NOTE: A special tool is available for use in installing the HO2S. An open-end wrench can be used for ease of installation. Install the RH HO2S sensors. ^ Tighten to 40 Nm (30 lb-ft). All engines 3. NOTE: Make sure to apply anti-seize lubricant to the threads of the sensors before installation. NOTE: A special tool is available for use in installing the catalyst monitor sensor. An open-end wrench can be used for ease of installation. Install the RH catalyst monitor. ^ Tighten to 40 Nm (30 lb-ft). 4. Loosely install the exhaust Y-pipe--dual catalytic converter hanger bracket and isolator and RH exhaust Y-pipe-dual catalytic converter hanger Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair > Page 2209 bracket and isolator bolt. Let the LH side of the exhaust Y-pipe-dual catalytic converter hanger bracket and isolator hang down. 4.6L and 5.4L engines 5. Connect the RH HO2S sensor electrical connector. All engines 6. NOTE: Using an abrasive pad, clean the exhaust clamp surface area of any surface rust. Position the LH catalytic converter and loosely install the exhaust manifold nuts. 7. NOTE: Make sure to apply anti-seize lubricant to the threads of the sensors before installation. NOTE: A special tool is available for use in installing the catalyst monitor sensor. An open-end wrench can be used for ease of installation. Install the LH catalyst monitor sensor. ^ Tighten to 40 Nm (30 lb-ft). 4.6L and 5.4L engine 8. NOTE: Make sure to apply anti-seize lubricant to the threads of the sensors before installation. NOTE: A special tool is available for use in installing the HO2S. An open-end wrench can be used for ease of installation. Install the LH HO2S sensor. ^ Tighten to 40 Nm (30 lb-ft). All engines 9. Loosely install the bolt for the LH side of the exhaust Y-pipe--dual catalytic converter hanger bracket and isolator. 10. Push the RH catalytic converter into place and loosely install the exhaust manifold nuts. 11. Make sure the catalytic converters are fully seated and the notch on the RH catalytic converter is aligned with the button on the LH catalytic converter. 12. Tighten the catalytic converter exhaust Torca(R) clamp to 47 Nm (35 lb-ft). 13. Align the RH catalytic converter (crossover pipe) so that it is parallel to the transmission crossmember. The maximum allowable angle is 1.0 degree. 14. Tighten the catalytic converter hanger bracket bolts to 30 Nm (22 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair > Page 2210 ^ Verify the RH catalytic converter (crossover pipe) is still aligned to the transmission crossmember. Realign as necessary. 15. NOTE: 4.6L and 5.4L shown, 4.2L similar. Tighten the LH catalytic converter-to-exhaust manifold nuts in the following sequence. ^ Tighten the lower nut to 20 Nm (15 lb-ft). ^ Tighten the upper nut to 40 Nm (30 lb-ft). ^ Tighten the lower nut to 40 Nm (30 lb-ft). 16. NOTE: 4.6L and 5.4L shown, 4.2L similar. Tighten the RH catalytic converter-to-exhaust manifold nuts in the following sequence. ^ Tighten the lower nut to 20 Nm (15 lb-ft). ^ Tighten the upper nut to 40 Nm (30 lb-ft). ^ Tighten the lower nut to 40 Nm (30 lb-ft). 17. Verify the gap between the RH catalytic converter-to-exhaust intermediate pipe is within specification. The maximum allowable gap is 5 mm (0.20 inch). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair > Page 2211 18. NOTE: Using an abrasive pad, clean the exhaust coupling surface area of any surface rust. Slide the exhaust coupler against the button, then tighten the exhaust coupler bolts to specification. Use the following sequence: ^ Tighten the front nut to 47 Nm (35 lb-ft). ^ Tighten the back nut to 47 Nm (35 lb-ft). ^ Tighten the front nut to 47 Nm (35 lb-ft). 19. NOTE: LH side shown, RH similar. Tighten the heat shield bolts to the transmission crossmember. ^ Tighten to 15 Nm (11 lb-ft). 4.6L and 5.4L engines 20. Connect the LH HO2S sensor electrical connectors. All engines 21. Connect the 2 catalyst monitor sensor electrical connectors. 22. If equipped, install the skid plate. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair > Page 2212 23. Check to see if the exhaust system isolators are at zero load. If the exhaust system isolators are not at zero load, then carry out the exhaust system alignment procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Studs ....................................................................................................................... ...................................................... 12 Nm (9 lb-ft). Discard the studs. Exhaust Manifold Nuts ......................................................................................................................... .................................................... 25 Nm (18 lb-ft). Discard the nuts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2216 Exhaust Manifold: Testing and Inspection Exhaust Manifold Cleaning and Inspection Special Tool(s) 1. Clean the exhaust manifold using a suitable solvent. Use a plastic scraping tool to clean the gasket sealing surfaces. 2. NOTE: New exhaust manifold gaskets, studs, nuts and/or bolts must be installed when an exhaust manifold is serviced. NOTE: Use a straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 inch) per running foot of length, such as Snap-On(R) GA438A or equivalent. For example, if the straightedge is 61 cm (24 inch) long, the machined edge must be flat within 0.010 mm (0.0004 inch) from end to end. Using the precision straight edge and a feeler gauge, check the exhaust manifold sealing surface for warpage. If the warpage is greater than 0.76 mm (0.0299 inch), install a new exhaust manifold. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - LH Exhaust Manifold: Service and Repair Exhaust Manifold - LH Exhaust Manifold - LH Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the LH inner fender well. 3. Remove the 2 exhaust Y-pipe flange nuts and position the exhaust Y-pipe flange aside. 4. Remove the EGR system module-to-exhaust manifold tube. 5. Remove and discard the 8 exhaust manifold nuts. 6. Remove the LH exhaust manifold and discard the gasket. 7. Remove and discard the 8 exhaust manifold-to-cylinder head studs. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - LH > Page 2219 8. Inspect the exhaust manifold for flatness. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces. Clean the sealing surfaces with metal surface prep. 2. Install 8 new exhaust manifold-to-cylinder head studs. ^ Tighten to 12 Nm (9 lb-ft). 3. NOTE: Install a new exhaust manifold gasket and new nuts. Position the gaskets and the LH exhaust manifold and tighten the nuts in the sequence shown. ^ Tighten to 25 Nm (18 lb-ft). 4. Install the EGR system module-to-exhaust manifold tube. ^ Tighten to 40 Nm (30 lb-ft). 5. Position the Y-pipe flange and install the 2 nuts. ^ Tighten to 40 Nm (30 lb-ft). 6. Install the LH inner fender well. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - LH > Page 2220 Exhaust Manifold: Service and Repair Exhaust Manifold - RH Exhaust Manifold - RH Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the starter. For additional information, refer to Starting System. 3. Remove the RH inner fender well. 4. Remove the 2 exhaust Y-pipe flange nuts and position the exhaust Y-pipe flange aside. 5. Remove and discard the 8 exhaust manifold nuts. 6. Remove the RH exhaust manifold and discard the gasket. 7. Remove and discard the 8 exhaust manifold-to-cylinder head studs. 8. Inspect the exhaust manifold for flatness. Installation Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - LH > Page 2221 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces. Clean the sealing surfaces with metal surface prep. 2. Install 8 new exhaust manifold-to-cylinder head studs. ^ Tighten to 12 Nm (9 lb-ft). 3. NOTE: Install a new exhaust manifold gasket and new nuts. Position the gasket and the RH exhaust manifold and tighten the nuts in the sequence shown. ^ Tighten to 25 Nm (18 lb-ft). 4. Position the Y-pipe flange and install the 2 nuts. ^ Tighten to 40 Nm (30 lb-ft). 5. Install the RH inner fender well. 6. Install the starter. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair Exhaust Pipe: Service and Repair Exhaust Intermediate Pipe Exhaust System - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2225 Exhaust System - Exploded View (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2226 Harley Davidson (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2227 Harley Davidson (Part 2) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Loosen the exhaust Y-pipe - dual catalytic converter-to-exhaust intermediate pipe coupling. Slide the coupling onto the intermediate pipe. 3. NOTE: If a new exhaust intermediate pipe-to-muffler assembly Torca(R) clamp is required, a new exhaust intermediate pipe and Torca(R) clamp assembly must be installed. Loosen the exhaust intermediate pipe-to-muffler and tailpipe Torca(R) clamp and remove the exhaust intermediate pipe from the vehicle. Installation 1. Position the exhaust intermediate pipe and Torca(R) clamp assembly to the muffler and tailpipe. 2. Push the muffler and tailpipe assembly forward until the collar on the tailpipe hanger bracket is touching the isolator. 3. NOTE: Using an abrasive pad, clean the exhaust clamp surface area of any surface rust. NOTE: If a new exhaust intermediate pipe-to-muffler assembly Torca(R) clamp is required, a new exhaust intermediate pipe and Torca(R) clamp assembly must be installed. Make sure the button on the muffler and tailpipe assembly inlet pipe is fully inserted into the L-notch on the exhaust intermediate pipe. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 2228 4. Verify the gap between the RH catalytic converter-to-exhaust intermediate pipe is within specification. The maximum allowable gap is 5 mm (0.20 inch). 5. NOTE: Using an abrasive pad, clean the exhaust coupling surface area of any surface rust. Slide the exhaust coupler against the button on the exhaust Y-Pipe-dual catalytic converter, then tighten the exhaust coupler bolts using the following sequence: ^ Tighten the front nut to 47 Nm (35 lb-ft). ^ Tighten the back nut to 47 Nm (35 lb-ft). ^ Tighten the front nut to 47 Nm (35 lb-ft). 6. NOTE: If a new exhaust intermediate pipe-to-muffler assembly Torca(R) clamp is required, a new exhaust intermediate pipe and Torca(R) clamp assembly must be installed. Tighten the exhaust intermediate pipe-to-muffler and tailpipe assembly exhaust Torca(R) clamp to 47 Nm (35 lb-ft). 7. Check to see if the exhaust system isolators are at zero load. If the exhaust system isolators are not at zero load, then carry out the exhaust system alignment procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair Muffler and Tailpipe Exhaust System - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2232 Exhaust System - Exploded View (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2233 Harley Davidson (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2234 Harley Davidson (Part 2) Removal CAUTION: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger bracket during vehicle operation. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. NOTE: If a new exhaust intermediate pipe-to-muffler assembly Torca(R) clamp is required, a new exhaust intermediate pipe and Torca(R) clamp assembly must be installed. Loosen the exhaust intermediate pipe-to-muffler and tailpipe assembly clamp. 3. Remove the bolt and the front muffler exhaust hanger bracket and isolator from the frame. 4. Remove the bolt and the rear muffler exhaust hanger bracket and isolator from the frame. 5. Remove the bolt and the tailpipe exhaust hanger bracket and isolator from the frame. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2235 6. Remove the muffler and tailpipe assembly. Installation 1. NOTE: Using an abrasive pad, clean the exhaust Torca(R) clamp surface area of any surface rust. Position the muffler and tailpipe assembly. 2. Install the front muffler exhaust hanger bracket and isolator to the frame. ^ Tighten to 30 Nm (22 lb-ft). 3. Install the rear muffler exhaust hanger bracket and isolator to the frame. ^ Tighten to 30 Nm (22 lb-ft). 4. Install the tailpipe exhaust hanger bracket and isolator to the frame. ^ Tighten to 30 Nm (22 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2236 5. Push the muffler and tailpipe assembly forward until the collar on the tailpipe hanger bracket is touching the isolator. 6. Make sure the button on the muffler and tailpipe assembly inlet pipe is fully inserted into the L-notch on the extension pipe. 7. NOTE: If a new exhaust intermediate pipe-to-muffler assembly Torca(R) clamp is required, a new exhaust intermediate pipe and Torca(R) clamp assembly must be installed. Tighten the exhaust intermediate pipe-to-muffler and tailpipe assembly exhaust clamp to 47 Nm (35 lb-ft). 8. Check to see if the exhaust system isolators are at zero load. If the exhaust system isolators are not at zero load, then carry out the exhaust system alignment procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The torque based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable camshaft timing (VCT) (deliver same torque during transitions). Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with smoother traction control. Other benefits of ETC are: eliminate cruise control actuators - eliminate idle air control (IAC) valve - better airflow range - packaging (no cable) - more responsive powertrain at altitude and improved shift quality The ETC system illuminates a powertrain malfunction indicator (wrench) on the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The ETB has the following characteristics: - The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). - There are 2 designs: parallel and in-line. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-line design has a separate motor housing. - An internal spring is used in both designs to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. - The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (approximately 0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. - The required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. - There is 1 reference voltage and 1 signal return circuit between the PCM and the ETB. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. There are also 2 TP signal circuits for redundancy. The redundant TP signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The TP2 signal reaches a limit of approximately 4.5 volts at approximately 45 degrees of throttle angle. Accelerator Pedal Position (APP) Sensor Depending on the application either a 2-track or 3-track APP sensor is used. Electronic Throttle Control (ETC) System Strategy ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2243 ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2244 ETC System With A 2-Track APP Sensor Failure Mode And Effects Management Electronic Throttle Monitor Operation Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2245 The torque based ETC strategy was developed to improve fuel economy and to accommodate variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain control processor unit (CPU) and a separate monitoring processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, appropriate corrective action is taken. APP and TP Sensor Inputs Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check Electronic Throttle Actuator Control (TAC) Output Electronic TAC Operation Check Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations Engine Control Module: Locations View 151-2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2249 View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2250 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2251 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2252 View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2253 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2254 View 151-12 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2257 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2258 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2259 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2260 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2261 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2262 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2263 Engine Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2264 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2265 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2266 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2267 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2268 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2269 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2270 Engine Control Module: Connector Views C175B (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2271 C175B (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2272 C175B (Part 3) C175E (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2273 C175E (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2274 C175T (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2275 C175T (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The EEPROM is contained in an integrated circuit internal to the powertrain control module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle, and is capable of being programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate DTCs PI635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for DTC P1639. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block is displayed on the scan tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the scan tool displays a message indicating the need to flash the PCM again to reset the VID block. Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the scan tool manufacturer's instruction manual for details. Programming the VID Block for a Replacement PCM A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the VID block is blank and needs programming. There are 2 procedures available. The first is an automatic data transfer from the old PCM to the new PCM, and the second is manual data entry into the new PCM. Automatic data transfer is carried out if the old PCM is capable of communicating. This is done by using a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can then be downloaded to the new PCM after it has been installed. Carry out manual data entry if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible scan tool, select and carry out the module/parameter programming, referring to the scan tool manufacturer's instruction manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in DTCs P1635 and P1639. You may be instructed to contact the As-Built Data Center for the information needed to manually update the VID block with the scan tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and Lincoln Mercury technicians, contact your National Hotline or the Professional Technician Society (PTS) website for As-Built data listed under the Service Publications Index. Non-Ford technicians use the Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search function to find the Module Programming or As-Built Data. For Ford and Lincoln Mercury technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to Module Reprogramming on the scan tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production, or the need to reset the VID block because it has reached its limit. Refer to Module Reprogramming on the scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2278 Engine Control Module: Removal and Replacement POWERTRAIN CONTROL MODULE (PCM) Removal 1. NOTE: Any PCM replacement will require that ALL customer keys are available to be reprogrammed at the time of installation. PCM replacement DOES NOT require new keys. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation procedure. 2. Disconnect the PCM electrical connectors. 3. Remove the bolts and the PCM. 4. If necessary, remove the bolts and the PCM bracket. Installation 1. If necessary, install the PCM bracket and the bolts. - Tighten to 10 Nm (89 lb-in). 2. Install the PCM and the bolts. - Tighten to 7 Nm (62 lb-in). 3. Connect the PCM electrical connectors. 4. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation procedure. 5. Reprogram the passive anti-theft system (PATS). Carry out the Key Programming Using Two Programmed Keys procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2282 Main Relay (Computer/Fuel System): Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations EGR Control Module: Locations View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations > Page 2287 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations > Page 2288 C1450 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 2293 C433 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 2294 Fuel Pump Control Unit: Service and Repair FUEL PUMP DRIVER MODULE (FPDM) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The fuel pump driver module (FPDM) is located above the spare tire. Disconnect the FPDM electrical connector. 3. Remove the FPDM bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2301 Main Relay (Computer/Fuel System): Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2307 C2251 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2308 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor 2-Track APP Sensor There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are 2 reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 3-Track APP Sensor Typical 3-Track APP Sensor There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APP2 and APP3, both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2312 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2313 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2314 C1454 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2315 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2316 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2317 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Open the clamp on the air cleaner and separate the tray from the cover. 2. Disconnect the mass air flow (MAF) sensor electrical connector and detach the connector retainer. 3. Remove the grommet from the air cleaner cover and slide it down the electrical harness. 4. Pull the air cleaner inner cover and MAF sensor out of the air cleaner cover. 5. Disconnect the MAF sensor electrical connector and remove the inner cover and MAF sensor assembly. 6. Remove the bolts and the MAF sensor. - To install, tighten to 2 Nm (18 lb-in). 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2322 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2323 Camshaft Position Sensor: Locations Camshaft Position Sensor View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2324 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor Camshaft Position Sensor: Diagrams Camshaft Position Sensor C180 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2327 C1180 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2328 C1366 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2329 C1367 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2330 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil on plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2331 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the camshaft position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. - Lubricate the CMP sensor O-ring seal with clean engine oil prior to installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 2335 C257 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 2336 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 2337 Clutch Switch: Service and Repair CLUTCH PEDAL POSITION (CPP) SWITCH Removal and Installation 1. Disconnect the clutch pedal position (CPP) switch electrical connector. 2. Detach the pushrod from the clutch lever pin. 3. Remove the CPP switch. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2341 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2342 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2343 C101 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2344 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2345 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Rotate the accessory drive belt clockwise and detach the accessory drive belt from the A/C compressor pulley. 3. Loosen the A/C compressor bolts enough to slide the A/C compressor down approximately 25 mm (1 in), to allow access to the crankshaft position (CKP) sensor. To install, tighten to 25 Nm (18 lb-ft). 4. Disconnect the CKP sensor electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2346 5. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 6. To install, reverse the removal procedure. - Lubricate the O-ring seal with clean engine oil prior to installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2350 C107 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2351 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2352 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Remove the generator. 2. Disconnect the cylinder head temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. - Apply anti-seize to the threads of the CHT sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL INPUT (FLI) The FLI is a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module Fuel Level Sensor: Service and Repair Fuel Pump Module FUEL PUMP MODULE Special Tool(s) Special Tool(s) Removal WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 2358 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the fuel tank. 3. Using soapy water, clean a minimum of 76 mm (3 in) surface area around the fuel pump module. 4. Disconnect the fuel supply and fuel vapor tube assembly quick connect couplings at the fuel pump module and remove the fuel supply and fuel vapor tube assembly from the fuel tank. 5. Using the special tool, remove the fuel pump module locking ring. 6. Lift the fuel pump module out of the fuel tank enough to disconnect the internal fuel tank grade vent valves-to-fuel pump quick connect coupling. 7. CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter. Remove the fuel pump module. 8. Remove and discard the fuel pump module O-ring seal. Installation 1. NOTE: Lubricate the new fuel pump module O-ring seal with clean engine oil prior to installation. Install a new fuel pump module O-ring seal. 2. CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter. Install the fuel pump module into the fuel tank enough to connect the internal fuel tank grade vent valves-to-fuel pump quick connect coupling. 3. Install the fuel pump module the rest of the way into the fuel tank. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 2359 4. Using the special tool, install the fuel pump module locking ring. 5. NOTE: - The fuel pump module does not come equipped with a fuel pump module cover from the factory. The fuel pump module cover is only installed after service to the fuel pump module is performed. - Before installing the fuel pump module cover, make sure it fits around all fuel and vapor ports and electrical connectors and allows enough clearance to install the fuel and vapor tube assembly and the fuel pump module electrical connector. - Make sure a minimum of 76 mm (3 in) surface area is properly cleaned of all gas, oil and foreign material before installing the fuel pump module cover. Install a fuel pump module cover over the fuel pump module and locking ring. 6. Install the fuel supply and fuel vapor tube assembly onto the fuel tank and connect the fuel supply and fuel vapor tube assembly quick connect couplings at the fuel pump module. 7. Install the fuel tank. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 2360 Fuel Level Sensor: Service and Repair Fuel Level Sender FUEL LEVEL SENDER Removal WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. 1. Remove the fuel pump module. 2. NOTE: Note the routing of the fuel level sender wire for installation. Unwrap the fuel level sender wire from the rest of the fuel pump module wire harness. 3. Remove the heat shrink tube covering the electrical connector. 4. Disconnect the electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 2361 5. NOTE: Gasoline shown, flexible fuel similar. Remove the screw and lift up to remove the fuel level sender. Installation All vehicles 1. Route the fuel level sender wire through the center of the fuel pump module. Gasoline vehicles 2. NOTE: - Both fuel level sender wires must be routed behind the metal fuel level sender plate. - The grounding eyelet must be on the front side of the fuel level sender. Hook the fuel level sender on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. Flexible fuel vehicles Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 2362 3. NOTE: - One fuel level sender wire routes behind the fuel level sender and one routes along the left side of the fuel level sender. - The grounding eyelet must be on the front side of the fuel level sender. Hook the fuel level sender on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. Clip the wire into the clip on the fuel pump module. All vehicles 4. Slide the heat shrink tube onto the wire harness and connect the electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, heat the heat shrink tube. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 2363 6. Wrap the fuel level sender wire around the fuel pump module wire harness to make sure the wire will not interfere with the movement of the fuel gauge sending unit float arm. 7. Install the fuel pump module. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2367 C435 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2368 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE (FTP) SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2372 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2373 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2374 C1454 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2375 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type MAF Sensor The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2376 fuel, spark, and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described above. One is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control spark and to help determine charge air cooler (CAC) efficiency. Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2377 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 2382 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 2383 Knock Sensor: Locations Knock Sensor View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 2384 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 C109 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 2387 C108 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 2388 Knock Sensor: Diagrams Knock Sensor C1512 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 2389 C1514 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2390 Knock Sensor: Description and Operation Knock Sensor (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2391 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Typical Manifold Absolute Pressure (MAP) Sensor The MAP sensor measures intake manifold absolute pressure. The PCM uses information from the MAP sensor to measure how much exhaust gas is introduced into the intake manifold. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation > Page 2398 Oil Temperature Sensor For ECM: Service and Repair OIL TEMPERATURE SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the oil drain plug and drain the engine oil. - To install, tighten to 23 Nm (17 lb-ft). 3. Disconnect the oil temperature sensor electrical connector. 4. Remove the oil temperature sensor. - To install, tighten to 21 Nm (15 lb-ft). 5. To install, reverse the removal procedure. - Inspect the oil temperature O-ring seal and install a new O-ring seal if necessary. - Fill the engine with clean engine oil. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #11/#21 View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 2403 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 2404 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 2405 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12/#22 View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 2406 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 2407 View 151-12 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 C141 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2410 C142 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2411 C171 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2412 C172 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2413 Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Heated Oxygen Sensor (HO2S) The HO2S detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by providing the ground when the correct conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Universal HO2S The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner, the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio. The measured air/fuel ratio is actually the output from the current controller in the PCM and not a signal that comes directly from the sensor. The universal HO2S also uses a self-contained reference chamber to make sure an oxygen differential is always present. The oxygen for the reference chamber is supplied by pumping small amounts of oxygen ions from the measurement chamber into the reference chamber. The universal HO2S does not need access to outside air. Part to part variance is compensated for by placing a resistor in the connector. This resistor is used to trim the current measured by the current controller in the PCM. Embedded with the sensing element is the universal H02S heater. The heater allows the engine to enter closed loop operation sooner. The heating element heats the sensor to a temperature of 780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on and off by providing the ground to maintain the sensor at the correct temperature for maximum accuracy. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) HEATED OXYGEN SENSOR (HO2S) Exploded View Special Tool(s) Special Tool(s) Removal And Installation 1. With the vehicle in NEUTRAL, position it on a hoist. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 2416 2. NOTE: If necessary, lubricate the heated oxygen sensor (HO2S) with penetrating and lock lubricant to assist in removal Using the special tool, remove the HO2S. To install, tighten to 46 Nm (34 lb-ft). 3. To install, reverse the removal procedure. - Apply anti-seize to the threads of the HO2S. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 2417 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 2418 2. NOTE: If necessary, lubricate the catalyst monitor sensor with penetrating and lock lubricant to assist in removal. Using the special tool, remove the catalyst monitor sensor. To install, tighten to 46 Nm (34 lb-ft). 3. To install, reverse the removal procedure. - Apply anti-seize to the threads of the catalyst monitor sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2422 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2423 C1311 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2424 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example, during parking maneuvers. Power Steering Pressure (PSP) Switch Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback EGR sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 2428 The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 2429 Pressure Feedback Exhaust Sensor: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal 1. Disconnect the EGR system module electrical connector. 2. Disconnect the EGR system module vacuum connector. 3. Disconnect the exhaust manifold-to-EGR system module tube from the EGR system module. 4. Remove the bolts, the EGR system module and the gasket. Discard the gasket. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old gasket. Clean the EGR system module gasket mating surfaces. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 2430 2. Install a new gasket with the raised circle facing the throttle body (TB) adapter. 3. Position the EGR system module and install the bolts. - Tighten to 25 Nm (18 lb-ft). 4. Connect the exhaust manifold-to-EGR system module tube the EGR system module. - Tighten to 40 Nm (30 lb-ft). 5. Connect the EGR system module vacuum connector. 6. Connect the EGR system module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2434 C189 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2435 Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The 2 ETB throttle position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. Throttle Position (TP) Sensor Typical TP Sensor The TP sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a 3-blade electrical connector that may be gold plated. The gold plating increases the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating conditions are: closed throttle (includes idle or deceleration) - part throttle (includes cruise or moderate acceleration) - wide open throttle (includes maximum acceleration or de-choke on crank) - throttle angle rate Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 Transmission Position Switch/Sensor: Locations View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 2439 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 2442 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 2443 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 2444 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 2445 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 2446 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 2447 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 2448 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 2449 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 2450 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 2451 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 2452 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 2453 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 2454 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 2455 C167 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 2456 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the selector lever cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 4. Loosen the digital transmission range (TR) sensor bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 2457 5. NOTE: The manual control lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 lb-in). 7. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever shaft outer nut. ^ Tighten to 33 Nm (24 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 2458 8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. With the manual control lever in overdrive connect the selector lever cable. 9. Lower the vehicle. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 2459 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Removal NOTE: The manual control lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the selector lever cable. Disconnect the selector lever cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 2460 3. Disconnect the digital transmission range (TR) electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 2461 Installation 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 2462 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 lb-ft). 5. Connect the digital TR sensor electrical connector. 6. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable end to the manual control lever with the lever in the (D) position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 2463 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor The OSS sensor provides the PCM with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information that is generated. Vehicle Speed Sensor (VSS) Typical Vehicle Speed Sensor (VSS) The VSS is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling, and torque converter clutch scheduling. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback EGR sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 2471 The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 2472 Pressure Feedback Exhaust Sensor: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal 1. Disconnect the EGR system module electrical connector. 2. Disconnect the EGR system module vacuum connector. 3. Disconnect the exhaust manifold-to-EGR system module tube from the EGR system module. 4. Remove the bolts, the EGR system module and the gasket. Discard the gasket. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old gasket. Clean the EGR system module gasket mating surfaces. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 2473 2. Install a new gasket with the raised circle facing the throttle body (TB) adapter. 3. Position the EGR system module and install the bolts. - Tighten to 25 Nm (18 lb-ft). 4. Connect the exhaust manifold-to-EGR system module tube the EGR system module. - Tighten to 40 Nm (30 lb-ft). 5. Connect the EGR system module vacuum connector. 6. Connect the EGR system module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2478 C2251 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2479 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor 2-Track APP Sensor There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are 2 reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 3-Track APP Sensor Typical 3-Track APP Sensor There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APP2 and APP3, both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2483 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2484 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2485 C1454 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2486 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2487 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2488 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Open the clamp on the air cleaner and separate the tray from the cover. 2. Disconnect the mass air flow (MAF) sensor electrical connector and detach the connector retainer. 3. Remove the grommet from the air cleaner cover and slide it down the electrical harness. 4. Pull the air cleaner inner cover and MAF sensor out of the air cleaner cover. 5. Disconnect the MAF sensor electrical connector and remove the inner cover and MAF sensor assembly. 6. Remove the bolts and the MAF sensor. - To install, tighten to 2 Nm (18 lb-in). 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Fuel Pressure Sensor/Switch: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2492 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2493 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2494 Fuel Pressure Sensor/Switch: Diagrams C173 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2495 C1475 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2496 Fuel Pressure Sensor/Switch: Description and Operation FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2497 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the fuel pressure and temperature sensor electrical connector. 3. Disconnect the fuel pressure and temperature sensor vacuum connector. 4. Remove the bolts and the fuel pressure and temperature sensor. - To install, tighten to 4 Nm (35 lb-in). 5. Remove and discard the O-ring seal. - Install a new O-ring seal and lubricate with clean engine oil prior to installation. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Temperature Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2501 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2502 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2503 Fuel Temperature Sensor: Diagrams C173 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2504 C1475 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2505 Fuel Temperature Sensor: Description and Operation FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2506 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the fuel pressure and temperature sensor electrical connector. 3. Disconnect the fuel pressure and temperature sensor vacuum connector. 4. Remove the bolts and the fuel pressure and temperature sensor. - To install, tighten to 4 Nm (35 lb-in). 5. Remove and discard the O-ring seal. - Install a new O-ring seal and lubricate with clean engine oil prior to installation. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-18 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2510 C282 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2511 Inertia Fuel Shutoff Switch: Description and Operation INERTIA FUEL SHUTOFF (IFS) SWITCH Typical Inertia Fuel Shutoff (IFS) Switch The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shutoff the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner's Literature, Roadside Emergencies for the location of the IFS switch. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2512 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. Remove the RH cowl side trim panel. 2. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 3. Remove the 2 IFS bolts and the IFS switch. - To install, tighten to 2 Nm (18 lb-in). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2516 C189 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2517 Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The 2 ETB throttle position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. Throttle Position (TP) Sensor Typical TP Sensor The TP sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a 3-blade electrical connector that may be gold plated. The gold plating increases the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating conditions are: closed throttle (includes idle or deceleration) - part throttle (includes cruise or moderate acceleration) - wide open throttle (includes maximum acceleration or de-choke on crank) - throttle angle rate Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2523 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2524 Camshaft Position Sensor: Locations Camshaft Position Sensor View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2525 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor Camshaft Position Sensor: Diagrams Camshaft Position Sensor C180 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2528 C1180 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2529 C1366 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2530 C1367 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2531 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil on plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2532 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the camshaft position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. - Lubricate the CMP sensor O-ring seal with clean engine oil prior to installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2536 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2537 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2538 C101 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2539 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2540 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Rotate the accessory drive belt clockwise and detach the accessory drive belt from the A/C compressor pulley. 3. Loosen the A/C compressor bolts enough to slide the A/C compressor down approximately 25 mm (1 in), to allow access to the crankshaft position (CKP) sensor. To install, tighten to 25 Nm (18 lb-ft). 4. Disconnect the CKP sensor electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2541 5. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 6. To install, reverse the removal procedure. - Lubricate the O-ring seal with clean engine oil prior to installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Part 1 Part 2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Page 2546 Removal and Installation NOTE: - When a new lock cylinder is installed, the tailgate lock cylinder, door lock cylinders and the ignition lock cylinder should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is to be used, the new key code is attached to a tag. - The individual door lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build a new lock cylinder to the current key code of the vehicle. 1. Remove the steering wheel. 2. Remove bolt and the lower steering column shroud. 3. NOTE: The steering column shift is shown, the floor console shift is similar. Position the ignition lock cylinder cover aside. 4. Disconnect the PATS transceiver electrical connector. 5. Remove the screw and the PATS transceiver. 6. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove the lock cylinder. 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 2551 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 2552 Knock Sensor: Locations Knock Sensor View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 2553 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 C109 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 2556 C108 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 2557 Knock Sensor: Diagrams Knock Sensor C1512 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 2558 C1514 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2559 Knock Sensor: Description and Operation Knock Sensor (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2560 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Item....................................................................................................................................................... ..............................................................Specification Fuel Pressure Engine running..................................................................................................................................... ..............................................193-310 kPa (28-45 psi) Key ON, engine OFF (KOEO)......................... ..................................................................................................................................240-310 kPa (35-45 psi) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2565 Fuel Pressure: Testing and Inspection FUEL SYSTEM PRESSURE TEST Special Tool(s) Special Tool(s) WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. 1. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. 2. NOTE: 5.4L shown, 4.6L and 4.2L similar. Install the special tools in line between the fuel supply tube and fuel rail. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2566 3. NOTE: The electrical connector was disconnected during fuel system pressure release. Connect the electrical connector. 4. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 5. Test the fuel system pressure to make sure it is within the specified range. 6. NOTE: - 5.4L shown, 4.6L and 4.2L similar. - Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Upon completion of the fuel system pressure test, open the drain valve on the special tool and relieve the fuel system pressure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Typical Diagnostic Reference Value Measured/PID Values 665 RPM .......................................................................................................... ..................................................................................................... Hot Idle Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair AIR CLEANER ELEMENT Exploded View Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. Detach the electrical connector retainer. 2. Loosen the clamp and disconnect the air cleaner outlet pipe from the air cleaner cover. - To install, tighten to 4 Nm (35 lb-in). 3. Open the clamp and detach the air cleaner cover from the air cleaner tray. 4. Remove the air cleaner element. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE Special Tool(s) Special Tool(s) 1. NOTE: The splash shield is located on the LH frame rail under the driver side door. Disconnect the splash shield and position aside. 2. Disconnect the electrical connector. 3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition switch to the OFF position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 2578 6. When fuel system service is complete, connect the electrical connector. 7. Reposition the splash shield and install a new pushpin. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Install the scan tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON. Select the appropriate vehicle and engine qualifier. Clear all DTCs and carry out a PCM reset. 10. Start the vehicle and check the fuel system for leaks. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing order........................................................................................................................................... ...........................................................1-3-7-2-6-5-4-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications Item....................................................................................................................................................... ..............................................................Specification Base timing........................................................................................................................................... ............................10° before top dead center (BTDC) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions TSB 08-7-6 04/14/08 SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008 Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part List. ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and 2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07. ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and extract broken spark plugs. SERVICE PROCEDURE The engine build date can be read on the left hand cam cover information sticker. To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before removal is attempted. CAUTION DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS COULD BE DAMAGED. Spark Plug Removal Procedure 1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and surrounding valve cover area with compressed air. 2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4 teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark plug back and forth at this point. NOTE COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL. CAUTION EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE. CAUTION DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST ONLY BE REMOVED WITH HAND TOOLS. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2589 3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the back and forth turning as needed until turning effort is reduced, and remove the spark plugs. NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. (Figure 1) Separated/Broken Spark Plug Removal If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of three modes. Refer to the appropriate removal procedure as required. a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2) b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head. (Figure 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2590 c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground shield. (Figure 4) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2591 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2592 Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the cylinder head. (Figure 6) NOTE THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD. IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL. 1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be removed. (Figure 7) 2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and protect the combustion chamber from contamination. (Figure 7) 3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4 reduced diameter threads on the tip end). a. Coat the end of the tap with general purpose grease. (Figure 8) b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K) is provided with service tool 303-1203 update to connect the tap to a 3/8" socket Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2593 drive. CAUTION DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED. 4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9) a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out. b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to prevent thread stripping. c. Install the nylon washer and jack nut until finger tight. d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool assembly. NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. Mode 2 Procedure: 1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug well and allow 15 minutes of soak time. 2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking care not to fracture the porcelain. 3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder head. Mode 3 Procedure: CAUTION DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2594 Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground electrode shield. (FIGURE 10) Porcelain Removal - Preparation CAUTION THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21 °C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF ADHESIVE. CAUTION DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR BONDING. 1. Remove any remaining electrode material from broken porcelain with long nose reach pliers. 2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the straw nozzle supplied with the brake cleaner can. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2595 3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2596 4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14) NOTE PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN. 5. Insert the completed assembly into the spark plug well and fully engage the pin into the porcelain. (Figure 15) 6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to flood the porcelain and pin. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2597 7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take care making sure the pin does not disengage the porcelain. (Figure 16). 8. Repeat Steps 6 and 7. 9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry compressed air. NOTE CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN. 10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed. 11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry compressed air. Porcelain Removal - Bonding Process CAUTION USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER HEAD. NOTE WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES. 1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator. (Figure 17) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2598 2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18). 3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2. 4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent starts to cure. 5. Reassemble a dry and clean collet and pin assembly. 6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of Loctite® 638TMare being used if it drips off the pin. 7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin. 8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain with a twisting motion to spread the bonding agent. 9. Add additional Loctite® 638TM, repeating Steps 6-8. 10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19). CAUTION A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE EXTRACTION IS ATTEMPTED. 11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C). 12. Repeat the bonding process for remaining cylinders as needed. Porcelain Removal - Extraction 1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded rod. 2. Install the washer and jack nut until finger tight against the tool pilot bushing. CAUTION ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL. 3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is free of the ground electrode. 4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder head. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2599 NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7) Porcelain Removal - Pin Slipped Out In the unlikely event that the pin does not remove the broken porcelain, this process can be repeated. Key elements to success are: ^ Clean and dry porcelain ^ Sufficient Loctite® 638TM Retaining Compound spread uniformly ^ Loctite(R) 638(TM) cure time and temperature ^ Preventing the threaded rod from rotating while removing the porcelain Replacement Supplies Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT080706 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 12405 01 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > General Specifications Spark Plug: Specifications General Specifications Item....................................................................................................................................................... ..............................................................Specification Spark plug gap..................................................................................................................................... ....................................1.32-1.42 mm (0.052-0.056 in) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > General Specifications > Page 2602 Torque Specifications Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2603 Spark Plug: Application and ID Item....................................................................................................................................................... ..............................................................Specification Spark plug............................................................................................................................................ ...................................................................AGSF-32N Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2604 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Install a new spark plug. 2. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. ^ Install new spark plugs. 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2605 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a Heli-Coil(R) insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by white or light gray spots and with a bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Install new spark plugs. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2606 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2607 Spark Plug: Service and Repair SPARK PLUGS Exploded View Removal and Installation 1. Remove the ignition coil-on-plug. 2. CAUTION: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. - If an original spark plug is used, make sure it is installed in the same cylinder from which it was taken. New spark plugs can be used in any cylinder. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2608 Remove the spark plugs. To install, tighten to 15 Nm (11 lb-ft). 3. Inspect the spark plugs. Install new spark plugs as necessary. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2612 Compression Check: Testing and Inspection Compression Test - Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of 5 compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test - Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2613 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75% of the highest reading. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance This engine is equipped with hydraulic lash adjusters. No adjustment is required. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2621 C2251 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2622 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor 2-Track APP Sensor There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are 2 reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 3-Track APP Sensor Typical 3-Track APP Sensor There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APP2 and APP3, both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2626 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2627 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2628 C1454 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2629 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2630 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2631 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Open the clamp on the air cleaner and separate the tray from the cover. 2. Disconnect the mass air flow (MAF) sensor electrical connector and detach the connector retainer. 3. Remove the grommet from the air cleaner cover and slide it down the electrical harness. 4. Pull the air cleaner inner cover and MAF sensor out of the air cleaner cover. 5. Disconnect the MAF sensor electrical connector and remove the inner cover and MAF sensor assembly. 6. Remove the bolts and the MAF sensor. - To install, tighten to 2 Nm (18 lb-in). 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2635 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2636 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2637 C1454 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2638 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type MAF Sensor The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2639 fuel, spark, and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described above. One is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control spark and to help determine charge air cooler (CAC) efficiency. Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2640 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations > Page 2644 C278 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations > Page 2645 Brake Signal: Description and Operation Brake Pedal Position (BPP) Switch Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Brake Pedal Switch (BPS)/Brake Deactivator Switch The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is not applied. When the brake pedal is applied, the normally closed switch opens and power is removed from the PCM. On some applications the normally closed BPS, along with the normally open BPP switch, are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not changing states when they were expected to, a diagnostic trouble code (DTC) is set by the PCM strategy. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2650 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2651 Camshaft Position Sensor: Locations Camshaft Position Sensor View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2652 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor Camshaft Position Sensor: Diagrams Camshaft Position Sensor C180 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2655 C1180 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2656 C1366 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2657 C1367 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2658 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil on plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2659 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the camshaft position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. - Lubricate the CMP sensor O-ring seal with clean engine oil prior to installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 2663 C257 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 2664 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 2665 Clutch Switch: Service and Repair CLUTCH PEDAL POSITION (CPP) SWITCH Removal and Installation 1. Disconnect the clutch pedal position (CPP) switch electrical connector. 2. Detach the pushrod from the clutch lever pin. 3. Remove the CPP switch. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2669 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2670 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2671 C101 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2672 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2673 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Rotate the accessory drive belt clockwise and detach the accessory drive belt from the A/C compressor pulley. 3. Loosen the A/C compressor bolts enough to slide the A/C compressor down approximately 25 mm (1 in), to allow access to the crankshaft position (CKP) sensor. To install, tighten to 25 Nm (18 lb-ft). 4. Disconnect the CKP sensor electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2674 5. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 6. To install, reverse the removal procedure. - Lubricate the O-ring seal with clean engine oil prior to installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2680 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2681 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2682 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2683 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2684 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2685 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2686 Data Link Connector: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2687 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2688 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2689 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2690 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2691 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2692 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2693 C251 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Electronic Throttle Control (Etc) Motor View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Electronic Throttle Control (Etc) Motor > Page 2698 Electronic Throttle Actuator: Locations Electronic Throttle Position Motor View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Electronic Throttle Control (Etc) Motor > Page 2699 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Diagrams > Electronic Throttle Control (ETC) Motor C1368 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Diagrams > Electronic Throttle Control (ETC) Motor > Page 2702 C1513 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Diagrams > Page 2703 Electronic Throttle Actuator: Description and Operation ELECTRONIC THROTTLE ACTUATOR CONTROL (TAC) Typical In-line TAC Design Typical Parallel TAC Design The electronic TAC is a DC motor controlled by the PCM (requires 2 wires). There are 2 designs for the TAC, parallel and in-line. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-line design has a separate motor housing. An internal spring is used in both designs to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (approximately 0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The torque based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable camshaft timing (VCT) (deliver same torque during transitions). Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with smoother traction control. Other benefits of ETC are: eliminate cruise control actuators - eliminate idle air control (IAC) valve - better airflow range - packaging (no cable) - more responsive powertrain at altitude and improved shift quality The ETC system illuminates a powertrain malfunction indicator (wrench) on the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The ETB has the following characteristics: - The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). - There are 2 designs: parallel and in-line. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-line design has a separate motor housing. - An internal spring is used in both designs to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. - The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (approximately 0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. - The required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. - There is 1 reference voltage and 1 signal return circuit between the PCM and the ETB. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. There are also 2 TP signal circuits for redundancy. The redundant TP signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The TP2 signal reaches a limit of approximately 4.5 volts at approximately 45 degrees of throttle angle. Accelerator Pedal Position (APP) Sensor Depending on the application either a 2-track or 3-track APP sensor is used. Electronic Throttle Control (ETC) System Strategy ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2707 ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2708 ETC System With A 2-Track APP Sensor Failure Mode And Effects Management Electronic Throttle Monitor Operation Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2709 The torque based ETC strategy was developed to improve fuel economy and to accommodate variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain control processor unit (CPU) and a separate monitoring processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, appropriate corrective action is taken. APP and TP Sensor Inputs Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check Electronic Throttle Actuator Control (TAC) Output Electronic TAC Operation Check Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations Engine Control Module: Locations View 151-2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2713 View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2714 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2715 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2716 View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2717 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2718 View 151-12 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2721 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2722 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2723 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2724 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2725 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2726 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2727 Engine Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2728 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2729 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2730 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2731 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2732 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2733 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2734 Engine Control Module: Connector Views C175B (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2735 C175B (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2736 C175B (Part 3) C175E (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2737 C175E (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2738 C175T (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2739 C175T (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The EEPROM is contained in an integrated circuit internal to the powertrain control module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle, and is capable of being programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate DTCs PI635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for DTC P1639. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block is displayed on the scan tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the scan tool displays a message indicating the need to flash the PCM again to reset the VID block. Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the scan tool manufacturer's instruction manual for details. Programming the VID Block for a Replacement PCM A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the VID block is blank and needs programming. There are 2 procedures available. The first is an automatic data transfer from the old PCM to the new PCM, and the second is manual data entry into the new PCM. Automatic data transfer is carried out if the old PCM is capable of communicating. This is done by using a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can then be downloaded to the new PCM after it has been installed. Carry out manual data entry if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible scan tool, select and carry out the module/parameter programming, referring to the scan tool manufacturer's instruction manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in DTCs P1635 and P1639. You may be instructed to contact the As-Built Data Center for the information needed to manually update the VID block with the scan tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and Lincoln Mercury technicians, contact your National Hotline or the Professional Technician Society (PTS) website for As-Built data listed under the Service Publications Index. Non-Ford technicians use the Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search function to find the Module Programming or As-Built Data. For Ford and Lincoln Mercury technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to Module Reprogramming on the scan tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production, or the need to reset the VID block because it has reached its limit. Refer to Module Reprogramming on the scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2742 Engine Control Module: Removal and Replacement POWERTRAIN CONTROL MODULE (PCM) Removal 1. NOTE: Any PCM replacement will require that ALL customer keys are available to be reprogrammed at the time of installation. PCM replacement DOES NOT require new keys. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation procedure. 2. Disconnect the PCM electrical connectors. 3. Remove the bolts and the PCM. 4. If necessary, remove the bolts and the PCM bracket. Installation 1. If necessary, install the PCM bracket and the bolts. - Tighten to 10 Nm (89 lb-in). 2. Install the PCM and the bolts. - Tighten to 7 Nm (62 lb-in). 3. Connect the PCM electrical connectors. 4. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation procedure. 5. Reprogram the passive anti-theft system (PATS). Carry out the Key Programming Using Two Programmed Keys procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2746 C107 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2747 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2748 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Remove the generator. 2. Disconnect the cylinder head temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. - Apply anti-seize to the threads of the CHT sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL INPUT (FLI) The FLI is a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module Fuel Level Sensor: Service and Repair Fuel Pump Module FUEL PUMP MODULE Special Tool(s) Special Tool(s) Removal WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 2754 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the fuel tank. 3. Using soapy water, clean a minimum of 76 mm (3 in) surface area around the fuel pump module. 4. Disconnect the fuel supply and fuel vapor tube assembly quick connect couplings at the fuel pump module and remove the fuel supply and fuel vapor tube assembly from the fuel tank. 5. Using the special tool, remove the fuel pump module locking ring. 6. Lift the fuel pump module out of the fuel tank enough to disconnect the internal fuel tank grade vent valves-to-fuel pump quick connect coupling. 7. CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter. Remove the fuel pump module. 8. Remove and discard the fuel pump module O-ring seal. Installation 1. NOTE: Lubricate the new fuel pump module O-ring seal with clean engine oil prior to installation. Install a new fuel pump module O-ring seal. 2. CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter. Install the fuel pump module into the fuel tank enough to connect the internal fuel tank grade vent valves-to-fuel pump quick connect coupling. 3. Install the fuel pump module the rest of the way into the fuel tank. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 2755 4. Using the special tool, install the fuel pump module locking ring. 5. NOTE: - The fuel pump module does not come equipped with a fuel pump module cover from the factory. The fuel pump module cover is only installed after service to the fuel pump module is performed. - Before installing the fuel pump module cover, make sure it fits around all fuel and vapor ports and electrical connectors and allows enough clearance to install the fuel and vapor tube assembly and the fuel pump module electrical connector. - Make sure a minimum of 76 mm (3 in) surface area is properly cleaned of all gas, oil and foreign material before installing the fuel pump module cover. Install a fuel pump module cover over the fuel pump module and locking ring. 6. Install the fuel supply and fuel vapor tube assembly onto the fuel tank and connect the fuel supply and fuel vapor tube assembly quick connect couplings at the fuel pump module. 7. Install the fuel tank. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 2756 Fuel Level Sensor: Service and Repair Fuel Level Sender FUEL LEVEL SENDER Removal WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. 1. Remove the fuel pump module. 2. NOTE: Note the routing of the fuel level sender wire for installation. Unwrap the fuel level sender wire from the rest of the fuel pump module wire harness. 3. Remove the heat shrink tube covering the electrical connector. 4. Disconnect the electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 2757 5. NOTE: Gasoline shown, flexible fuel similar. Remove the screw and lift up to remove the fuel level sender. Installation All vehicles 1. Route the fuel level sender wire through the center of the fuel pump module. Gasoline vehicles 2. NOTE: - Both fuel level sender wires must be routed behind the metal fuel level sender plate. - The grounding eyelet must be on the front side of the fuel level sender. Hook the fuel level sender on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. Flexible fuel vehicles Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 2758 3. NOTE: - One fuel level sender wire routes behind the fuel level sender and one routes along the left side of the fuel level sender. - The grounding eyelet must be on the front side of the fuel level sender. Hook the fuel level sender on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. Clip the wire into the clip on the fuel pump module. All vehicles 4. Slide the heat shrink tube onto the wire harness and connect the electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, heat the heat shrink tube. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 2759 6. Wrap the fuel level sender wire around the fuel pump module wire harness to make sure the wire will not interfere with the movement of the fuel gauge sending unit float arm. 7. Install the fuel pump module. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2763 C435 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2764 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE (FTP) SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation Idle Speed/Throttle Actuator - Electronic: Description and Operation IDLE AIR CONTROL (IAC) VALVE NOTE: The IAC valve assembly is not adjustable and cannot be cleaned, also some IAC valves are normally open and others are normally closed. Some IAC valves require engine vacuum to operate. The IAC valve assembly controls the engine idle speed and provides a dashpot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine RPM and increases or decreases the IAC duty cycle in order to achieve the desired RPM. The PCM uses the IAC valve assembly to control: - no touch start - cold engine fast idle for rapid warm-up - idle (corrects for engine load) - stumble or stalling on deceleration (provides a dashpot function) - over-temperature idle boost Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2772 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2773 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2774 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2775 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2776 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2777 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2778 Information Bus: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2779 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2780 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2781 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2782 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2783 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2784 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2785 Information Bus: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 14-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2786 14-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2787 Information Bus: Description and Operation COMMUNICATIONS NETWORK Vehicle communication utilizes a high speed controller area network (HS-CAN), International Standards Organization (ISO) 9141 network and universal asynchronous receiver-transmitter (UART)-based protocol (UBP) network. Information is sent to and from individual control modules that each control specific functions. All 3 networks are connected to the data link connector (DLC). The DLC can be found under the instrument panel between the steering column and the audio control module (ACM). The 3 module communication networks are: - High speed (HS) CAN - ISO 9141 - UBP ISO 9141 is for diagnostic use only while UBP and CAN allow multiple modules to communicate, or transfer data, with each other on a common network. NOTE: The ACM, rear entertainment module (RETM) and satellite digital audio receiver system (SDARS) module communicate on a non-standard medium speed controller area network (MS-CAN) bus which cannot be accessed by the IDS through the data link connector (DLC). Network Topology Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2788 ISO 9141 Network Operation The ISO 9141 communication network is a single wire network, used for diagnostic purposes only. The ISO 9141 communication network is used for the following modules: Restraints control module (RCM) - Parking aid module (PAM) UART-Based Protocol (UBP) Communication Network The UBP communication network is a single wire network. In addition to scan tool communication, this network allows sharing of information between all modules on the network. The UBP communication network is used for the following modules: Driver seat module (DSM) - Heating ventilation air conditioning (HVAC) module - Instrument cluster (IC) - Vehicle security module (VSM) HS-CAN Operation The HS-CAN uses an unshielded twisted pair cable, data bus (+) and data bus (-) circuits. In addition to scan tool communication, this network allows sharing of information between all modules on the network. The HS-CAN is a high speed communication network used for the following modules: PCM with integrated 4X4 control module - ABS module - IC Network Termination The CAN uses a network termination circuit to improve communication reliability. The network termination of the CAN bus takes place inside the termination modules by termination resistors. Termination modules are located at either end of the bus network. As network messages are broadcast, in the form of voltage signals, the network voltage signals are stabilized by the termination resistors. Each termination module has a 120 ohm resistor across the positive and negative bus connection in the termination module. With two termination modules on each network, and the 120 ohm resistors located in a parallel circuit configuration, the total network impedance, or total resistance is 60 ohms. Network termination improves bus message reliability by: Stabilizing bus voltage - Eliminating electrical interference Gateway Module The instrument cluster is the gateway module, translating HS-CAN to UBP and vice versa. This information allows a message to be distributed throughout both networks. The instrument cluster is the only module on this vehicle that has this ability. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Central junction box (CJB) fuse(s): 1 (10A) (instrument cluster [IC]) - 3 (7.5A) (driver seat module [DSM]) - 5 (7.5A) (heating ventilation air conditioning [HVAC] module) - 13 (10A) (HVAC module) - 14 (10A) (ABS module) - 15 (5A) (IC) - 18 (10A) (vehicle security module [VSM], parking aid module [PAM]) - 19 (10A) (RCM) - 21 (15A) (IC) - 27 (5A) (IC) - 103 (20A) (ABS module) - 107 (30A) (VSM) - 109 (30A) (DSM) - 110 (20A) (no power to scan tool) - 112 (40A) (ABS) - Data link connector (DLC) - Wiring, terminals or connectors 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the DLC. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - GO to Pinpoint Test M, to diagnose no power to the scan tool. See: Pinpoint Tests/Test M: No Power To The Scan Tool 5. NOTE: During the network test, the scan tool will first attempt to communicate with the PCM, after establishing communication with the PCM, the scan tool will then attempt to communicate with all other modules on the vehicle. Carry out the network test. If the network test passes, retrieve and record the continuous memory DTCs and proceed to Step 6. - If the network test fails, GO to Symptom Chart to identify the module not communicating. See: Symptom Related Diagnostic Procedures 6. If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to Body Control Systems (Multifunction Electronic Control Module). See: Diagnostic Trouble Code Descriptions/Module Communications Network 7. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Principles of Operation PRINCIPLES OF OPERATION Vehicle communication utilizes a high speed controller area network (HS-CAN), International Standards Organization (ISO) 9141 network and universal asynchronous receiver/transmitter (UART) based protocol (UBP) network. Information is sent to and from individual control modules that each control specific functions. All 3 networks are connected to the data link connector (DLC). The DLC can be found under the instrument panel between the steering column and the audio control module (ACM). The 3 module communication networks are: - High speed (HS) CAN Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2791 - ISO 9141 - UBP ISO 9141 Communications Network The ISO 9141 communications network is a single wire network. The ISO 9141 communications network does not permit intermodule communication. When the scan tool communicates to modules on the ISO 9141 communication network, the scan tool must request all information; the modules cannot initiate communications. The ISO 9141 network operates at a maximum data transfer speed of 10.4 Kbps. The following modules are on the ISO 9141 network: Parking aid module (PAM) (if equipped) - Restraints control module (RCM) The following fault chart describes the specific ISO 9141 network failures and their resulting symptom: ISO 9141 Network Communication Fault Chart HS-CAN The HS-CAN uses an unshielded twisted pair cable of data (+) and data (-) circuits. The data (+) and the data (-) circuits are each regulated to approximately 2.5 volts during neutral or rested network traffic. As bus messages are sent on the data (+) circuit, voltage is increased by approximately 1.0 volt. Inversely, the data (-) circuit is reduced by approximately 1.0 volt when a bus message is sent. Multiple bus messages can be sent over the CAN circuits allowing network modules to communicate with each other. The CAN bus (+) and bus (-) circuits must always be terminated. The network termination of the CAN bus takes place inside the 2 termination modules, the PCM and the instrument cluster (IC), by resistors rated at 120 ohms, located across the (+) and (-) circuits. The resistors are wired in parallel to the network bus circuits for a total operating resistance of 60 ohms on a good network. The HS-CAN operates at a maximum data transfer speed of 500 Kbps and remains operational at a degraded level when certain circuit faults are present. The HS-CAN bus may remain operational with only one termination resistor present. The following modules are on the HS-CAN: ABS module - IC - PCM with integrated 4X4 control module The following fault chart describes the specific HS-CAN failures and their resulting symptom: Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2792 HS-CAN Communication Fault Chart Universal Asynchronous Receiver-Transmitter (UART)-Based Protocol (UBP) Communications Network The UBP communications network is a single circuit communications network, circuit 1906 (VT). The UBP communications network does not function if the wire is shorted to ground or voltage. The UBP communications network allows intermodule communication. The UBP network operates at a maximum data transfer speed of 9.6 Kbps. The UBP network circuit is regulated to approximately 12.0 volts during neutral or rested network traffic. This voltage is reduced proportional to the volume of bus messages sent. The following modules are on the UBP network: Heating ventilation air conditioning (HVAC) module (if equipped) - Driver seat module (DSM) (if equipped) - Instrument cluster (IC) - Vehicle security module (VSM) The following fault chart describes the specific UBP network failures and their resulting symptom: UBP Network Communication Fault Chart The following chart describes all network messages broadcast on HS-CAN, SCP and UBP by each module, and the module(s) that receive the message: Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2793 Network Module Communication Message Chart (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2794 Network Module Communication Message Chart (Part 2) Inspection and Verification INSPECTION AND VERIFICATION This provides step-by-step module configuration procedures. Carry out the programmable module installation (PMI) procedure when another Vehicle System directs to carry out configuration or when DTCs from the below list are present: See: Programming and Relearning NOTE: DTCs retrieved from the audio control module (ACM), rear entertainment module (RETM), or satellite digital audio receiver system (SDARS) module during an ACM self-test are addressed in Radio, Stereo and Compact Disc. Principles of Operation PRINCIPLES OF OPERATION Configurable modules accommodate a variety of vehicle options, eliminating the need for many unique modules for one vehicle line. These modules Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2795 must be configured when replaced as part of a repair procedure. Configurable modules should not be exchanged between vehicles since the settings are unique to each vehicle. Failure to configure a new module may result in improper operation and/or any of the following DTCs setting: - B2477 and/or B2141 - sets when a body/chassis module is not configured. - B2900 - sets when there is a VIN mismatch between the module with the B2900 and the PCM. Either the PCM or the body module stored VIN may be incorrect. - P0602, P0605 and/or P1639 - sets when the PCM vehicle identification (VID) block is not configured or is configured incorrectly. - U0300 and/or U0301 - sets when the configuration between 2 or more modules do not match. - U2050 and/or U2051 - sets when a valid strategy/calibration is not present. The following are the 3 different methods of configuration: - Programmable module installation (PMI) - Module reprogramming ("flashing") - Programmable parameters Some modules do not support all 3 methods. Definition of Terms The following are definitions of configuration terms: Programmable Module Installation (PMI) PMI is a scan tool process which configures settings in a new module. Data used for the PMI process is automatically downloaded from the original module and stored when a scan tool session is started. If this data cannot be retrieved from the module being replaced, the scan tool may prompt for As-Built data entry or display a list of parameter values that need to be manually selected. Some modules are reprogrammed during PMI when a strategy/calibration update is available. NOTE: A module must be able to communicate with the scan tool in order to carry out PMI. It is important that the scan tool identifies the vehicle and obtains configuration data prior to removing any modules. See: Programming and Relearning To carry out PMI, refer to Programmable Module Installation. See: Programming and Relearning Module Reprogramming Module reprogramming (also referred to as "flashing") is a scan tool process which updates the strategy/calibration in a module. Module reprogramming is automatically carried out during PMI when a later strategy/calibration is available. Reprogramming a module with the same level of software will not improve module operation or repair a hardware failure. NOTE: - Module reprogramming should be limited to circumstances where a published Technical Service Bulletin (TSB) procedure recommends doing so. - A module cannot communicate with other modules on the communication network while being reprogrammed. Clear any network communication DTCs which may have been set in other modules during reprogramming. Programmable Parameters Programmable parameters are customer preference items that may be modified by the dealer via scan tool or in some cases modified by the customer following a procedure listed in the vehicle Owner's Literature. While many configuration options may exist for a module, only a few of these options are programmable parameters. Adaptive Learning and Calibration Some modules require a separate learning procedure be carried out if replaced as part of a repair procedure. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. Vehicle Identification (VID) Block Some PCMs contain a memory area called a vehicle identification (VID) block. The PCM VID block commonly stores powertrain configuration items such as VIN, tire size, axle ratio, and whether or not the vehicle is equipped with speed control. As-Built Data As-Built data is a VIN specific module configuration record. During vehicle build, the configuration from all modules is downloaded and stored in the As-Built database. As-Built data will not reflect customer preference items that have been changed from the default state. These items will need to be changed using programmable parameters after the module is configured. NOTE: It is not necessary to obtain As-Built data unless directed to do so by the scan tool. This data may be accessed from the technician service publication website. The following chart lists body/chassis module As-Built data addresses: Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2796 Body/Chassis Module Addresses for As-Built Entry The following chart describes specific module programming information: NOTE: The audio control module (ACM), rear entertainment module (RETM) and satellite digital audio receiver system (SDARS) module communicate on a non-standard MS-CAN bus which cannot be accessed by the IDS through the data link connector (DLC). Module Configuration and Parameter Index (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2797 Module Configuration and Parameter Index (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2798 Information Bus: Diagnostic Trouble Code Descriptions Module Communications Network DTC U0073-U1950 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2799 DTC U2023-U2471 B2477 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2800 B2900 / P0602-P1639 / U2050-U2051 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2801 Information Bus: Symptom Related Diagnostic Procedures Symptom Chart (1 Of 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2802 Symptom Chart (2 Of 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2803 Information Bus: Pinpoint Tests Test A: The PCM Does Not Respond To The Scan Tool PINPOINT TEST A: THE PCM DOES NOT RESPOND TO THE SCAN TOOL Normal Operation The PCM communicates with the scan tool through the high speed controller area network (HS-CAN). Circuits 1827 (WH/LG) (HS-CAN +) and 1828 (PK/LG) (HS-CAN -) provide the network connection to the PCM. The PCM shares the HS-CAN with the ABS module and the instrument cluster (IC). This pinpoint is intended to diagnose the following: - Wiring, terminals or connectors - PCM A1-A2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2804 A2-A3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2805 A4 Test B: The ABS Module Does Not Respond To The Scan Tool PINPOINT TEST B: THE ABS MODULE DOES NOT RESPOND TO THE SCAN TOOL Normal Operation The ABS module communicates with the scan tool through the high speed controller area network (HS-CAN). Circuits 1827 (WH/LG) (HS-CAN +) and 1828 (PK/LG) (HS-CAN -) provide the network connection to the ABS module. The ABS module shares the HS-CAN with the PCM and the instrument cluster (IC). Voltage for the ABS module is provided by circuits 295 (LB/PK), 532 (OG/YE) and 534 (YE/LG). Ground is provided by circuit 530 (LG/YE). This pinpoint is intended to diagnose the following: - Fuses - Wiring, terminals or connectors - ABS module B1-B2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2806 B2-B4 Test C: The Instrument Cluster (IC) Does Not Respond To The Scan Tool PINPOINT TEST C: THE INSTRUMENT CLUSTER (IC) DOES NOT RESPOND TO THE SCAN TOOL Normal Operation The IC communicates with the scan tool through the high speed controller area network (HS-CAN) and communicates with other modules on the UBP communication network. Circuits 1827 (WH/LG) (HS-CAN +) and 1828 (PK/LG) (HS-CAN -) provide the HS-CAN connection to the IC and circuit 1906 (VT) provides the UBP network connection to the IC. The IC shares the HS-CAN with the PCM and the ABS module. In addition, the IC shares the UBP network with the vehicle security module (VSM) (if equipped), the heating ventilation air conditioning (HVAC) module (if equipped) and the driver seat module (DSM) (if equipped). Voltage for the IC is provided by circuits 640 (RD/YE), 489 (PK/BK), 1003 (GY/YE) and 3049 (BK/LG). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2807 Circuits 57 (BK) and 875 (BK/LB) provide ground. This pinpoint is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - IC C1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2808 C2-C3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2809 C4-C5 Test D: The Heating Ventilation Air Conditioning (HVAC) Module Does Not Respond To The Scan Tool PINPOINT TEST D: THE HEATING VENTILATION AIR CONDITIONING (HVAC) MODULE DOES NOT RESPOND TO THE SCAN TOOL Normal Operation The HVAC module communicates with the scan tool through the UBP communication network. Circuit 1906 (VT) provides the network connection to the HVAC module. The HVAC module shares the UBP network with the instrument cluster (IC), the vehicle security module (VSM) (if equipped) and the driver seat module (DSM) (if equipped). Voltage for the HVAC module is provided by circuits 296 (WH/VT) and 729 (RD/WH). Circuit 875 (BK/LB) provides ground. This pinpoint is intended to diagnose the following: - Fuses - Wiring, terminals or connectors - HVAC module Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2810 D1-D3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2811 D3-D4 Test E: The Vehicle Security Module (VSM) Does Not Respond To The Scan Tool PINPOINT TEST E: THE VEHICLE SECURITY MODULE (VSM) DOES NOT RESPOND TO THE SCAN TOOL Normal Operation The VSM communicates with the scan tool through the UBP communication network. Circuit 1906 (VT) provides the network connection to the VSM. The VSM shares the UBP network with the heating ventilation air conditioning (HVAC) module (if equipped), the driver seat module (DSM) (if equipped) and the instrument cluster (IC). Voltage for the VSM is provided by circuits 7 (LG/YE) and 294 (WH/LB). Circuits 57 (BK) and 938 (BK/LG) provide ground. This pinpoint is intended to diagnose the following: - Fuses - Wiring, terminals or connectors - VSM Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2812 E1-E2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2813 E3-E4 Test F: The Driver Seat Module (DSM) Does Not Respond To The Scan Tool PINPOINT TEST F: THE DRIVER SEAT MODULE (DSM) DOES NOT RESPOND TO THE SCAN TOOL Normal Operation The DSM communicates with the scan tool through the UBP communication network. Circuit 1906 (VT) provides the network connection to the DSM. The DSM shares the UBP network with the heating ventilation air conditioning (HVAC) module (if equipped), the vehicle security module (VSM) (if equipped), and the instrument cluster (IC). Voltage for the DSM is provided by circuits 566 (DG) and 956 (OG/LG). Circuits 57 (BK) and 875 (BK/LB) provide ground. This pinpoint is intended to diagnose the following: - Fuses - Wiring, terminals or connectors - DSM Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2814 F1-F2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2815 F3-F4 Test G: The Restraints Control Module (RCM) Does Not Respond To The Scan Tool PINPOINT TEST G: THE RESTRAINTS CONTROL MODULE (RCM) DOES NOT RESPOND TO THE SCAN TOOL Normal Operation The RCM communicates with the scan tool through the International Standards Organization (ISO) 9141 communication network. Circuit 70 (LB/WH) provides the network connection to the RCM. The RCM shares the ISO network with the parking aid module (PAM) (if equipped). Voltage for the RCM is provided by circuit 937 (RD/WH). Circuit 1203 (BK/LB) provides ground. This pinpoint is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - RCM Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2816 G1-G2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2817 G2-G4 Test H: The Parking Aid Module (PAM) Does Not Respond To The Scan Tool PINPOINT TEST H: THE PARKING AID MODULE (PAM) DOES NOT RESPOND TO THE SCAN TOOL Normal Operation The PAM communicates with the scan tool through the International Standards Organization (ISO) 9141 communications network. Circuit 70 (LB/WH) provides the network connection to the PAM. The PAM shares the ISO network with the restraints control module (RCM). Voltage for the PAM is provided by circuit 294 (WH/LB). Ground is provided by circuit 875 (BK/LB). This pinpoint is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - PAM Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2818 H1-H2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2819 H3-H4 Test I: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding PINPOINT TEST I: NO HIGH SPEED CONTROLLER AREA NETWORK (HS-CAN) COMMUNICATION, ALL MODULES ARE NOT RESPONDING Normal Operation The HS-CAN uses an unshielded twisted pair cable, circuits 1827 (WH/LG) and 1828 (PK/LG). The ABS module, the instrument cluster (IC) and PCM all communicate with the scan tool using the HS-CAN. This pinpoint is intended to diagnose the following: - Wiring, terminals or connectors - ABS module - IC - PCM I1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2820 I1-I2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2821 I3-I4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2822 I5-I6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2823 I7-I8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2824 I8-I10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2825 I10-I11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2826 I12-I14 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2827 I14-I16 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2828 I16-I19 Test J: Intermittent No High Speed Controller Area Network (HS-CAN) Communication, One Or More Modules Are Not Responding Durin PINPOINT TEST J: INTERMITTENT NO HIGH SPEED CONTROLLER AREA NETWORK (HS-CAN) COMMUNICATION, ONE OR MORE MODULES ARE NOT RESPONDING DURING NETWORK TEST Normal Operation Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2829 The HS-CAN is used for communication between the PCM, the ABS module and the instrument cluster (IC). An open circuit VDB04 (WH/BU) (HS-CAN +) or VDB05 (WH) (HS-CAN -) may cause intermittent or unreliable communication to all modules on the HS-CAN. In the event that either circuit VDB04 (WH/BU) (HS-CAN +) or VDB05 (WH) (HS-CAN -) becomes open to any module on the network, unreliable network communication to all modules on the network may result. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors J1-J2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2830 J2-J4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2831 J4-J7 Test K: No International Standards Organization (ISO) 9141 Network Communication PINPOINT TEST K: NO INTERNATIONAL STANDARDS ORGANIZATION (ISO) 9141 NETWORK COMMUNICATION Normal Operation The restraints control module (RCM) and the parking aid module (PAM) communicate with the scan tool through the ISO 9141 communication network, circuit 70 (LB/WH). This pinpoint is intended to diagnose the following: Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2832 - Wiring, terminals or connectors - RCM - PAM K1-K4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2833 K5-K8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2834 K8-K10 Test L: No Universal Asynchronous Receiver-Transmitter (UART)-Based Protocol (UBP) Network Communication PINPOINT TEST L: NO UNIVERSAL ASYNCHRONOUS RECEIVER-TRANSMITTER (UART)-BASED PROTOCOL (UBP) NETWORK COMMUNICATION Normal Operation The UBP network is comprised of the driver seat module (DSM) (if equipped), the heating ventilation air conditioning (HVAC) module (if equipped), the vehicle security module (VSM) (if equipped) and the instrument cluster (IC). The IC does not communicate with the scan tool on the UBP network but does communicate with the other UBP network modules, if equipped. This pinpoint is intended to diagnose the following: - Wiring, terminals or connectors - DSM - HVAC module - IC - VSM Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2835 L1-L3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2836 L3-L6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2837 L7-L13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2838 L14-L16 Test M: No Power To The Scan Tool PINPOINT TEST M: NO POWER TO THE SCAN TOOL Normal Operation The scan tool connects to the data link connector (DLC) to communicate with the controller area network (CAN), universal asynchronous receiver-transmitter (UART)-based protocol (UBP) communications network and the international standards organization (ISO) 9141 communications networks. This pinpoint is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Scan tool Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2839 M1-M2 M3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2840 Information Bus: Programming and Relearning PROGRAMMABLE MODULE INSTALLATION Special Tool(s) Special Tool(s) Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The Original Module Is Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For instructions, refer to the specific module removal and installation procedures. 1. Connect the IDS and identify the vehicle as normal. 2. From the Toolbox icon, select Module Programming and press the check mark. 3. Select Programmable Module Installation. 4. Select the module that is being replaced. 5. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 6. Install the new module and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. The IDS downloads the data into the new module and displays Module Configuration Complete. 9. Test module for correct operation. Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The Original Module Is Not Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. 1. Install the new module. 2. Connect the IDS and identify the vehicle as normal. 3. From the Toolbox icon, select Module Programming and press the check mark. 4. Select Programmable Module Installation. 5. Select the module that was replaced. 6. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. If the data is not available, the IDS displays a screen stating to contact the As-Built Data Center. Retrieve the data from the technician service publication website at this time and press the check mark. 9. Enter the module data and press the check mark. 10. The IDS downloads the data into the new module and displays Module Configuration Complete. 11. Test module for correct operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Page 2841 Information Bus: Service and Repair PROGRAMMABLE MODULE INSTALLATION Special Tool(s) Special Tool(s) Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The Original Module Is Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For instructions, refer to the specific module removal and installation procedures. 1. Connect the IDS and identify the vehicle as normal. 2. From the Toolbox icon, select Module Programming and press the check mark. 3. Select Programmable Module Installation. 4. Select the module that is being replaced. 5. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 6. Install the new module and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. The IDS downloads the data into the new module and displays Module Configuration Complete. 9. Test module for correct operation. Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The Original Module Is Not Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. 1. Install the new module. 2. Connect the IDS and identify the vehicle as normal. 3. From the Toolbox icon, select Module Programming and press the check mark. 4. Select Programmable Module Installation. 5. Select the module that was replaced. 6. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. If the data is not available, the IDS displays a screen stating to contact the As-Built Data Center. Retrieve the data from the technician service publication website at this time and press the check mark. 9. Enter the module data and press the check mark. 10. The IDS downloads the data into the new module and displays Module Configuration Complete. 11. Test module for correct operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Tools and Equipment > Module Communications Network Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Tools and Equipment > Module Communications Network > Page 2844 Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 2849 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 2850 Knock Sensor: Locations Knock Sensor View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 2851 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 C109 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 2854 C108 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 2855 Knock Sensor: Diagrams Knock Sensor C1512 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 2856 C1514 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2857 Knock Sensor: Description and Operation Knock Sensor (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2858 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2862 Main Relay (Computer/Fuel System): Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) Check Engine, Service Engine Soon, Or ISO Standard Engine Symbol The MIL notifies the driver that the powertrain control module (PCM) has detected an on board diagnostic (OBD) emission-related component or system concern. When this occurs, an OBD diagnostic trouble code (DTC) sets. - The MIL is located in the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or the international standards organization (ISO) standard engine symbol. - The MIL is illuminated during the instrument cluster prove out for approximately 4 seconds. - The MIL remains illuminated after instrument cluster prove out if: an emission-related concern and DTC exists. - the PCM does not send a control message to the instrument cluster (applications with the MIL controlled through the communication link). - the PCM is operating in the hardware limited operation strategy (HLOS). - The MIL remains off during the instrument cluster prove out if an indicator or instrument cluster concern is present. - To turn off the MIL after a repair, a reset command from the scan tool must be sent, or 3 consecutive drive cycles must be completed without a concern. - For all MIL concerns, go to Symptom Charts. See: Testing and Inspection/Symptom Related Diagnostic Procedures - If the MIL flashes at a steady rate, a severe misfire condition may exist. - If the MIL flashes erratically, the PCM can reset while cranking if the battery voltage is low. - The MIL flashes after a period of time with the key in the RUN position (engine not running) if DTC P1000 is set. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Typical Manifold Absolute Pressure (MAP) Sensor The MAP sensor measures intake manifold absolute pressure. The PCM uses information from the MAP sensor to measure how much exhaust gas is introduced into the intake manifold. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation > Page 2872 Oil Temperature Sensor For ECM: Service and Repair OIL TEMPERATURE SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the oil drain plug and drain the engine oil. - To install, tighten to 23 Nm (17 lb-ft). 3. Disconnect the oil temperature sensor electrical connector. 4. Remove the oil temperature sensor. - To install, tighten to 21 Nm (15 lb-ft). 5. To install, reverse the removal procedure. - Inspect the oil temperature O-ring seal and install a new O-ring seal if necessary. - Fill the engine with clean engine oil. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #11/#21 View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 2877 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 2878 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 2879 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12/#22 View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 2880 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 2881 View 151-12 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 C141 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2884 C142 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2885 C171 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2886 C172 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2887 Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Heated Oxygen Sensor (HO2S) The HO2S detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by providing the ground when the correct conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Universal HO2S The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner, the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio. The measured air/fuel ratio is actually the output from the current controller in the PCM and not a signal that comes directly from the sensor. The universal HO2S also uses a self-contained reference chamber to make sure an oxygen differential is always present. The oxygen for the reference chamber is supplied by pumping small amounts of oxygen ions from the measurement chamber into the reference chamber. The universal HO2S does not need access to outside air. Part to part variance is compensated for by placing a resistor in the connector. This resistor is used to trim the current measured by the current controller in the PCM. Embedded with the sensing element is the universal H02S heater. The heater allows the engine to enter closed loop operation sooner. The heating element heats the sensor to a temperature of 780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on and off by providing the ground to maintain the sensor at the correct temperature for maximum accuracy. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) HEATED OXYGEN SENSOR (HO2S) Exploded View Special Tool(s) Special Tool(s) Removal And Installation 1. With the vehicle in NEUTRAL, position it on a hoist. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 2890 2. NOTE: If necessary, lubricate the heated oxygen sensor (HO2S) with penetrating and lock lubricant to assist in removal Using the special tool, remove the HO2S. To install, tighten to 46 Nm (34 lb-ft). 3. To install, reverse the removal procedure. - Apply anti-seize to the threads of the HO2S. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 2891 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 2892 2. NOTE: If necessary, lubricate the catalyst monitor sensor with penetrating and lock lubricant to assist in removal. Using the special tool, remove the catalyst monitor sensor. To install, tighten to 46 Nm (34 lb-ft). 3. To install, reverse the removal procedure. - Apply anti-seize to the threads of the catalyst monitor sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2896 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2897 C1311 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2898 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example, during parking maneuvers. Power Steering Pressure (PSP) Switch Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback EGR sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 2902 The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 2903 Pressure Feedback Exhaust Sensor: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal 1. Disconnect the EGR system module electrical connector. 2. Disconnect the EGR system module vacuum connector. 3. Disconnect the exhaust manifold-to-EGR system module tube from the EGR system module. 4. Remove the bolts, the EGR system module and the gasket. Discard the gasket. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old gasket. Clean the EGR system module gasket mating surfaces. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 2904 2. Install a new gasket with the raised circle facing the throttle body (TB) adapter. 3. Position the EGR system module and install the bolts. - Tighten to 25 Nm (18 lb-ft). 4. Connect the exhaust manifold-to-EGR system module tube the EGR system module. - Tighten to 40 Nm (30 lb-ft). 5. Connect the EGR system module vacuum connector. 6. Connect the EGR system module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The torque based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable camshaft timing (VCT) (deliver same torque during transitions). Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with smoother traction control. Other benefits of ETC are: eliminate cruise control actuators - eliminate idle air control (IAC) valve - better airflow range - packaging (no cable) - more responsive powertrain at altitude and improved shift quality The ETC system illuminates a powertrain malfunction indicator (wrench) on the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The ETB has the following characteristics: - The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). - There are 2 designs: parallel and in-line. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-line design has a separate motor housing. - An internal spring is used in both designs to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. - The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (approximately 0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. - The required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. - There is 1 reference voltage and 1 signal return circuit between the PCM and the ETB. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. There are also 2 TP signal circuits for redundancy. The redundant TP signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The TP2 signal reaches a limit of approximately 4.5 volts at approximately 45 degrees of throttle angle. Accelerator Pedal Position (APP) Sensor Depending on the application either a 2-track or 3-track APP sensor is used. Electronic Throttle Control (ETC) System Strategy ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2909 ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2910 ETC System With A 2-Track APP Sensor Failure Mode And Effects Management Electronic Throttle Monitor Operation Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2911 The torque based ETC strategy was developed to improve fuel economy and to accommodate variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain control processor unit (CPU) and a separate monitoring processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, appropriate corrective action is taken. APP and TP Sensor Inputs Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check Electronic Throttle Actuator Control (TAC) Output Electronic TAC Operation Check Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations Engine Control Module: Locations View 151-2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2915 View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2916 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2917 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2918 View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2919 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2920 View 151-12 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2923 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2924 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2925 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2926 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2927 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2928 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2929 Engine Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2930 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2931 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2932 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2933 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2934 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2935 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2936 Engine Control Module: Connector Views C175B (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2937 C175B (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2938 C175B (Part 3) C175E (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2939 C175E (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2940 C175T (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2941 C175T (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The EEPROM is contained in an integrated circuit internal to the powertrain control module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle, and is capable of being programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate DTCs PI635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for DTC P1639. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block is displayed on the scan tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the scan tool displays a message indicating the need to flash the PCM again to reset the VID block. Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the scan tool manufacturer's instruction manual for details. Programming the VID Block for a Replacement PCM A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the VID block is blank and needs programming. There are 2 procedures available. The first is an automatic data transfer from the old PCM to the new PCM, and the second is manual data entry into the new PCM. Automatic data transfer is carried out if the old PCM is capable of communicating. This is done by using a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can then be downloaded to the new PCM after it has been installed. Carry out manual data entry if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible scan tool, select and carry out the module/parameter programming, referring to the scan tool manufacturer's instruction manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in DTCs P1635 and P1639. You may be instructed to contact the As-Built Data Center for the information needed to manually update the VID block with the scan tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and Lincoln Mercury technicians, contact your National Hotline or the Professional Technician Society (PTS) website for As-Built data listed under the Service Publications Index. Non-Ford technicians use the Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search function to find the Module Programming or As-Built Data. For Ford and Lincoln Mercury technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to Module Reprogramming on the scan tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production, or the need to reset the VID block because it has reached its limit. Refer to Module Reprogramming on the scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2944 Engine Control Module: Removal and Replacement POWERTRAIN CONTROL MODULE (PCM) Removal 1. NOTE: Any PCM replacement will require that ALL customer keys are available to be reprogrammed at the time of installation. PCM replacement DOES NOT require new keys. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation procedure. 2. Disconnect the PCM electrical connectors. 3. Remove the bolts and the PCM. 4. If necessary, remove the bolts and the PCM bracket. Installation 1. If necessary, install the PCM bracket and the bolts. - Tighten to 10 Nm (89 lb-in). 2. Install the PCM and the bolts. - Tighten to 7 Nm (62 lb-in). 3. Connect the PCM electrical connectors. 4. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation procedure. 5. Reprogram the passive anti-theft system (PATS). Carry out the Key Programming Using Two Programmed Keys procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2948 Main Relay (Computer/Fuel System): Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2953 C2251 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2954 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor 2-Track APP Sensor There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are 2 reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 3-Track APP Sensor Typical 3-Track APP Sensor There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APP2 and APP3, both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2958 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2959 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2960 C1454 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2961 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2962 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2963 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Open the clamp on the air cleaner and separate the tray from the cover. 2. Disconnect the mass air flow (MAF) sensor electrical connector and detach the connector retainer. 3. Remove the grommet from the air cleaner cover and slide it down the electrical harness. 4. Pull the air cleaner inner cover and MAF sensor out of the air cleaner cover. 5. Disconnect the MAF sensor electrical connector and remove the inner cover and MAF sensor assembly. 6. Remove the bolts and the MAF sensor. - To install, tighten to 2 Nm (18 lb-in). 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2968 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2969 Camshaft Position Sensor: Locations Camshaft Position Sensor View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2970 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor Camshaft Position Sensor: Diagrams Camshaft Position Sensor C180 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2973 C1180 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2974 C1366 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2975 C1367 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2976 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil on plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2977 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the camshaft position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. - Lubricate the CMP sensor O-ring seal with clean engine oil prior to installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 2981 C257 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 2982 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 2983 Clutch Switch: Service and Repair CLUTCH PEDAL POSITION (CPP) SWITCH Removal and Installation 1. Disconnect the clutch pedal position (CPP) switch electrical connector. 2. Detach the pushrod from the clutch lever pin. 3. Remove the CPP switch. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2987 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2988 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2989 C101 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2990 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2991 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Rotate the accessory drive belt clockwise and detach the accessory drive belt from the A/C compressor pulley. 3. Loosen the A/C compressor bolts enough to slide the A/C compressor down approximately 25 mm (1 in), to allow access to the crankshaft position (CKP) sensor. To install, tighten to 25 Nm (18 lb-ft). 4. Disconnect the CKP sensor electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2992 5. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 6. To install, reverse the removal procedure. - Lubricate the O-ring seal with clean engine oil prior to installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2996 C107 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2997 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2998 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Remove the generator. 2. Disconnect the cylinder head temperature (CHT) sensor electrical connector. 3. Remove the CHT sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. - Apply anti-seize to the threads of the CHT sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL INPUT (FLI) The FLI is a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module Fuel Level Sensor: Service and Repair Fuel Pump Module FUEL PUMP MODULE Special Tool(s) Special Tool(s) Removal WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 3004 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the fuel tank. 3. Using soapy water, clean a minimum of 76 mm (3 in) surface area around the fuel pump module. 4. Disconnect the fuel supply and fuel vapor tube assembly quick connect couplings at the fuel pump module and remove the fuel supply and fuel vapor tube assembly from the fuel tank. 5. Using the special tool, remove the fuel pump module locking ring. 6. Lift the fuel pump module out of the fuel tank enough to disconnect the internal fuel tank grade vent valves-to-fuel pump quick connect coupling. 7. CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter. Remove the fuel pump module. 8. Remove and discard the fuel pump module O-ring seal. Installation 1. NOTE: Lubricate the new fuel pump module O-ring seal with clean engine oil prior to installation. Install a new fuel pump module O-ring seal. 2. CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter. Install the fuel pump module into the fuel tank enough to connect the internal fuel tank grade vent valves-to-fuel pump quick connect coupling. 3. Install the fuel pump module the rest of the way into the fuel tank. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 3005 4. Using the special tool, install the fuel pump module locking ring. 5. NOTE: - The fuel pump module does not come equipped with a fuel pump module cover from the factory. The fuel pump module cover is only installed after service to the fuel pump module is performed. - Before installing the fuel pump module cover, make sure it fits around all fuel and vapor ports and electrical connectors and allows enough clearance to install the fuel and vapor tube assembly and the fuel pump module electrical connector. - Make sure a minimum of 76 mm (3 in) surface area is properly cleaned of all gas, oil and foreign material before installing the fuel pump module cover. Install a fuel pump module cover over the fuel pump module and locking ring. 6. Install the fuel supply and fuel vapor tube assembly onto the fuel tank and connect the fuel supply and fuel vapor tube assembly quick connect couplings at the fuel pump module. 7. Install the fuel tank. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 3006 Fuel Level Sensor: Service and Repair Fuel Level Sender FUEL LEVEL SENDER Removal WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. 1. Remove the fuel pump module. 2. NOTE: Note the routing of the fuel level sender wire for installation. Unwrap the fuel level sender wire from the rest of the fuel pump module wire harness. 3. Remove the heat shrink tube covering the electrical connector. 4. Disconnect the electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 3007 5. NOTE: Gasoline shown, flexible fuel similar. Remove the screw and lift up to remove the fuel level sender. Installation All vehicles 1. Route the fuel level sender wire through the center of the fuel pump module. Gasoline vehicles 2. NOTE: - Both fuel level sender wires must be routed behind the metal fuel level sender plate. - The grounding eyelet must be on the front side of the fuel level sender. Hook the fuel level sender on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. Flexible fuel vehicles Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 3008 3. NOTE: - One fuel level sender wire routes behind the fuel level sender and one routes along the left side of the fuel level sender. - The grounding eyelet must be on the front side of the fuel level sender. Hook the fuel level sender on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. Clip the wire into the clip on the fuel pump module. All vehicles 4. Slide the heat shrink tube onto the wire harness and connect the electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, heat the heat shrink tube. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module > Page 3009 6. Wrap the fuel level sender wire around the fuel pump module wire harness to make sure the wire will not interfere with the movement of the fuel gauge sending unit float arm. 7. Install the fuel pump module. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3013 C435 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3014 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE (FTP) SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3018 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3019 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3020 C1454 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3021 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type MAF Sensor The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3022 fuel, spark, and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described above. One is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control spark and to help determine charge air cooler (CAC) efficiency. Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3023 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 3028 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 3029 Knock Sensor: Locations Knock Sensor View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 3030 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 C109 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 3033 C108 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 3034 Knock Sensor: Diagrams Knock Sensor C1512 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 3035 C1514 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3036 Knock Sensor: Description and Operation Knock Sensor (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3037 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Typical Manifold Absolute Pressure (MAP) Sensor The MAP sensor measures intake manifold absolute pressure. The PCM uses information from the MAP sensor to measure how much exhaust gas is introduced into the intake manifold. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation > Page 3044 Oil Temperature Sensor For ECM: Service and Repair OIL TEMPERATURE SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the oil drain plug and drain the engine oil. - To install, tighten to 23 Nm (17 lb-ft). 3. Disconnect the oil temperature sensor electrical connector. 4. Remove the oil temperature sensor. - To install, tighten to 21 Nm (15 lb-ft). 5. To install, reverse the removal procedure. - Inspect the oil temperature O-ring seal and install a new O-ring seal if necessary. - Fill the engine with clean engine oil. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #11/#21 View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 3049 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 3050 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 3051 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12/#22 View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 3052 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11/#21 > Page 3053 View 151-12 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 C141 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3056 C142 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3057 C171 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3058 C172 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3059 Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Heated Oxygen Sensor (HO2S) The HO2S detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by providing the ground when the correct conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Universal HO2S The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner, the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio. The measured air/fuel ratio is actually the output from the current controller in the PCM and not a signal that comes directly from the sensor. The universal HO2S also uses a self-contained reference chamber to make sure an oxygen differential is always present. The oxygen for the reference chamber is supplied by pumping small amounts of oxygen ions from the measurement chamber into the reference chamber. The universal HO2S does not need access to outside air. Part to part variance is compensated for by placing a resistor in the connector. This resistor is used to trim the current measured by the current controller in the PCM. Embedded with the sensing element is the universal H02S heater. The heater allows the engine to enter closed loop operation sooner. The heating element heats the sensor to a temperature of 780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on and off by providing the ground to maintain the sensor at the correct temperature for maximum accuracy. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) HEATED OXYGEN SENSOR (HO2S) Exploded View Special Tool(s) Special Tool(s) Removal And Installation 1. With the vehicle in NEUTRAL, position it on a hoist. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3062 2. NOTE: If necessary, lubricate the heated oxygen sensor (HO2S) with penetrating and lock lubricant to assist in removal Using the special tool, remove the HO2S. To install, tighten to 46 Nm (34 lb-ft). 3. To install, reverse the removal procedure. - Apply anti-seize to the threads of the HO2S. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3063 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3064 2. NOTE: If necessary, lubricate the catalyst monitor sensor with penetrating and lock lubricant to assist in removal. Using the special tool, remove the catalyst monitor sensor. To install, tighten to 46 Nm (34 lb-ft). 3. To install, reverse the removal procedure. - Apply anti-seize to the threads of the catalyst monitor sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3068 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3069 C1311 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3070 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example, during parking maneuvers. Power Steering Pressure (PSP) Switch Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback EGR sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3074 The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3075 Pressure Feedback Exhaust Sensor: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal 1. Disconnect the EGR system module electrical connector. 2. Disconnect the EGR system module vacuum connector. 3. Disconnect the exhaust manifold-to-EGR system module tube from the EGR system module. 4. Remove the bolts, the EGR system module and the gasket. Discard the gasket. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old gasket. Clean the EGR system module gasket mating surfaces. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3076 2. Install a new gasket with the raised circle facing the throttle body (TB) adapter. 3. Position the EGR system module and install the bolts. - Tighten to 25 Nm (18 lb-ft). 4. Connect the exhaust manifold-to-EGR system module tube the EGR system module. - Tighten to 40 Nm (30 lb-ft). 5. Connect the EGR system module vacuum connector. 6. Connect the EGR system module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3080 C189 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3081 Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The 2 ETB throttle position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. Throttle Position (TP) Sensor Typical TP Sensor The TP sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a 3-blade electrical connector that may be gold plated. The gold plating increases the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating conditions are: closed throttle (includes idle or deceleration) - part throttle (includes cruise or moderate acceleration) - wide open throttle (includes maximum acceleration or de-choke on crank) - throttle angle rate Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 Transmission Position Switch/Sensor: Locations View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 3085 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3088 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3089 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3090 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3091 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3092 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3093 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3094 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3095 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3096 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3097 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3098 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3099 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3100 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3101 C167 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 3102 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the selector lever cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 4. Loosen the digital transmission range (TR) sensor bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 3103 5. NOTE: The manual control lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 lb-in). 7. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever shaft outer nut. ^ Tighten to 33 Nm (24 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 3104 8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. With the manual control lever in overdrive connect the selector lever cable. 9. Lower the vehicle. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 3105 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Removal NOTE: The manual control lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the selector lever cable. Disconnect the selector lever cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 3106 3. Disconnect the digital transmission range (TR) electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 3107 Installation 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 3108 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 lb-ft). 5. Connect the digital TR sensor electrical connector. 6. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable end to the manual control lever with the lever in the (D) position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 3109 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor The OSS sensor provides the PCM with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information that is generated. Vehicle Speed Sensor (VSS) Typical Vehicle Speed Sensor (VSS) The VSS is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling, and torque converter clutch scheduling. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3116 C189 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3117 Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The 2 ETB throttle position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. Throttle Position (TP) Sensor Typical TP Sensor The TP sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a 3-blade electrical connector that may be gold plated. The gold plating increases the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating conditions are: closed throttle (includes idle or deceleration) - part throttle (includes cruise or moderate acceleration) - wide open throttle (includes maximum acceleration or de-choke on crank) - throttle angle rate Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3121 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3124 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3125 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3126 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3127 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3128 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3129 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3130 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3131 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3132 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3133 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3134 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3135 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3136 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3137 C167 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3138 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the selector lever cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 4. Loosen the digital transmission range (TR) sensor bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3139 5. NOTE: The manual control lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 lb-in). 7. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever shaft outer nut. ^ Tighten to 33 Nm (24 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3140 8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. With the manual control lever in overdrive connect the selector lever cable. 9. Lower the vehicle. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3141 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Removal NOTE: The manual control lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the selector lever cable. Disconnect the selector lever cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3142 3. Disconnect the digital transmission range (TR) electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3143 Installation 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3144 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 lb-ft). 5. Connect the digital TR sensor electrical connector. 6. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable end to the manual control lever with the lever in the (D) position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3145 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 C1451 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 3150 C1452 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3151 Variable Valve Timing Actuator: Description and Operation VARIABLE CAMSHAFT TIMING (VCT) SYSTEM Overview The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are 4 types of VCT systems. - Exhaust phase shifting (EPS) system - the exhaust cam is the active cam being retarded. - Intake phase shifting (IPS) system - the intake cam is the active cam being advanced. - Dual equal phase shifting (DEPS) system - both intake and exhaust cams are phase shifted and equally advanced or retarded. - Dual independent phase shifting (DIPS) system - where both the intake and exhaust cams are shifted independently. All systems have 4 operational modes: idle, part throttle, wide open throttle (WOT), and default mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM) determines the phase angle based on air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque. In addition, some VCT system applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used. Variable Camshaft Timing (VCT) System VCT System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A crankshaft position (CKP) sensor provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, engine oil temperature (EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part and wide open throttle, the camshaft position is determined by engine RPM, load and throttle position. The VCT system does not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle. The PCM calculates and determines the desired camshaft position. It continually updates the VCT solenoid duty cycle until the desired position is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3152 disables the VCT and places the camshaft in a default position if a concern is detected. A related DTC is also set when the concern is detected. 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor The OSS sensor provides the PCM with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information that is generated. Vehicle Speed Sensor (VSS) Typical Vehicle Speed Sensor (VSS) The VSS is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling, and torque converter clutch scheduling. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Solenoid > Component Information > Description and Operation Air Diverter Solenoid: Description and Operation SECONDARY AIR INJECTION (AIR) BYPASS SOLENOID Secondary AIR Bypass Solenoid The secondary AIR bypass solenoid is used by the PCM to control vacuum to the secondary air injection diverter (AIR diverter) valve. The secondary AIR bypass solenoid is a normally closed solenoid. The secondary AIR bypass solenoid also has a filtered vent feature to permit vacuum release. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation Air Diverter Valve: Description and Operation SECONDARY AIR DIVERTER VALVE Secondary AIR Diverter Valve The secondary AIR diverter valve is used with the secondary AIR pump to provide on/off control of air to the exhaust manifold and catalytic converter. When the secondary AIR pump is on and vacuum is supplied to the AIR diverter valve, air passes the integral check valve disk. When the secondary AIR pump is off, and vacuum is removed from the AIR diverter valve, the integral check valve disk is held on the seat and stops air from being drawn into the exhaust system and prevents the back flow of the exhaust into the secondary AIR system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Description and Operation Air Injection Pump: Description and Operation SECONDARY AIR PUMP Secondary Air Pump The secondary AIR pump provides pressurized air to the secondary AIR system. The secondary AIR pump functions independently of RPM and is controlled by the PCM. The secondary AIR pump is only used for short periods of time. Delivery of air is dependent on the amount of system backpressure and system voltage. The secondary AIR pump draws dry filtered air from the intake air system downstream of the MAF/IAT sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation CATALYST AND EXHAUST SYSTEMS Overview V-Engines In-Line Engines The catalytic converter and exhaust systems work together to control the release of harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of nitrogen (N), carbon dioxide (CO2) and water vapor (H2O). However, it also contains carbon monoxide (CO), oxides of nitrogen (NOx), hydrogen (H), and various unburned hydrocarbons (HCs). The major air pollutants of CO, NOx,and HCs, and their emission into the atmosphere must be controlled. The exhaust system generally consists of an exhaust manifold, front exhaust pipe, front heated oxygen sensor (HO2S), rear exhaust pipe, catalyst HO2S, a muffler, and an exhaust tailpipe. The catalytic converter is typically installed between the front and rear exhaust pipes. On some vehicle applications, more than one catalyst is used between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the on board diagnostic (OBD) system strategy in the powertrain control module (PCM). For information on the OBD catalyst monitor, refer to the description for the Catalyst Efficiency Monitor. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes/Catalyst Efficiency Monitor For most vehicles, only 2 HO2Ss are used in an exhaust stream. The front sensors (HO2S11/HO2S21) before the catalyst are used for primary fuel control while the ones after the catalyst (HO2S12/HO2S22) are used to monitor catalyst efficiency. However, some partial zero emission vehicles (PZEV) use 3 HO2Ss for each engine bank. The stream 1 sensors (HO2S11/HO2S21) located before the catalyst are used for primary fuel control, the stream 2 sensors (HO2S12/HO2S22) are used to monitor the light-off catalyst, and the stream 3 sensors (HO2S13/HO2S23) located after the catalyst are used for long term fuel trim control to optimize catalyst efficiency (fore aft oxygen sensor control). Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst also enables a chemical reaction to occur at a lower temperature. The concentration of exhaust gas products released to the atmosphere must be controlled. The catalytic Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3170 converter assists in this task. It contains a catalyst in the form of a specially treated ceramic honeycomb structure saturated with catalytically active precious metals. As the exhaust gases come in contact with the catalyst, they are changed into mostly harmless products. The catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components so they are used up as much as possible. Light Off Catalyst As the catalyst heats up, converter efficiency rises rapidly. The point at which conversion efficiency exceeds 50% is called catalyst light off. For most catalysts this point occurs at 246°C to 302°C (475°F to 575°F). A fast light catalyst is a 3-way catalyst (TWC) that is located as close to the exhaust manifold as possible. Because the light off catalyst is located close to the exhaust manifold it lights off faster and reduces emissions more quickly than the catalyst located under the body. Once the catalyst lights off, the catalyst quickly reaches the maximum conversion efficiency for that catalyst. Three-Way Catalyst (TWC) Conversion Efficiency TWC Conversion Efficiency Chart A TWC requires a stoichiometric fuel ratio, 14.7 pounds of air to 1 pound of fuel (14.7:1), for high conversion efficiency. In order to achieve these high efficiencies, the air/fuel ratio must be tightly controlled with a narrow window of stoichiometry. Deviations outside of this window greatly decrease the conversion efficiency. For example a rich mixture decreases the HC and CO conversion efficiency while a lean mixture decreases the NOx conversion efficiency. Exhaust System Typical Bank 1 Catalyst 2 HO2S Configuration Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3171 Typical Bank 1 Catalyst 3 HO2S Configuration The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. A HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of CO, unburned HCs, and NOx in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter past another HO2S mounted in the rear exhaust pipe and then on into the muffler. Finally, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. On some PZEV, there is a total of 3 HO2S in the exhaust stream. One near the exhaust manifold (stream 1), one in the middle of the light-off catalyst (stream 2), and the third (stream 3) is mounted after the light-off catalyst. Underbody Catalyst The underbody catalyst is located after the light off catalyst. The underbody catalyst may be in line with the light off catalyst, or the underbody catalyst may be common to 2 light off catalysts, forming a Y pipe configuration. For an exact configuration of the catalyst and exhaust system for a specific vehicle, refer to Exhaust System for the exhaust system-exploded view. Three-Way Catalytic (TWC) Converter The TWC converter contains either platinum (Pt) and rhodium (Rh) or palladium (Pd) and rhodium (Rh). The TWC converter catalyzes the oxidation reactions of unburned HCs and CO and the reduction reaction of NOx. The 3-way conversion can be best accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Exhaust Manifold Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on the engine configuration and number of cylinders. Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. Heated Oxygen Sensor (HO2S) The HO2Ss provide the PCM with information related to the oxygen content of the exhaust gas. Muffler Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The muffler reduces the level of noise produced by the engine, and also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams C123 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3176 Canister Purge Control Valve: Description and Operation EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VALVE Typical EVAP Canister Purge Valve NOTE: The EVAP canister purge valve may also be referred to as a vapor management valve (VMV). The EVAP canister purge valve is part of the enhanced EVAP system that is controlled by the PCM. This valve controls the flow of vapors (purging) from the EVAP canister to the intake manifold during various engine operating modes. The EVAP canister purge valve is a normally closed valve. The EVAP canister purge valve controls the flow of vapors by way of a solenoid, eliminating the need for an electronic vacuum regulator and vacuum diaphragm. The PCM outputs a signal between 0 mA and 1,000 mA to control the EVAP canister purge valve. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3177 Canister Purge Control Valve: Service and Repair EVAPORATIVE EMISSION CANISTER PURGE VALVE Evaporative Emission (EVAP) Canister Purge Valve Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3178 EVAP Canister Assembly - Removal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3179 EVAP Canister Assembly - Disassembly Exploded View Removal and Installation WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. 1. Disconnect the battery ground cable. 2. Disconnect the evaporative emission (EVAP) canister purge valve electrical connector. 3. Disconnect the 2 fuel vapor tube quick connect couplings. 4. Release the EVAP canister purge valve bracket tab and remove the EVAP canister purge valve. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service and Repair Evaporative Canister Filter: Service and Repair DUST SEPARATOR Evaporative Emission (EVAP) Canister Purge Valve Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service and Repair > Page 3183 EVAP Canister Assembly - Removal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service and Repair > Page 3184 EVAP Canister Assembly - Disassembly Exploded View Removal and Installation WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. NOTE: The evaporative emission (EVAP) canister assembly is located above the spare tire. Remove the spare tire. 4. Disconnect the fuel vapor tube quick connect coupling. 5. Disconnect the fuel vapor hose. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service and Repair > Page 3185 6. Remove the 2 front EVAP canister assembly bracket bolts. - To install, tighten to 13 Nm (10 lb-ft). 7. Remove the 2 outer rear EVAP canister assembly bracket bolts. - To install, tighten to 20 Nm (15 lb-ft). 8. Remove the 2 inner rear EVAP canister assembly bracket bolts. - To install, tighten to 13 Nm (10 lb-ft). 9. Lower the EVAP canister assembly down slightly to disconnect the EVAP canister vent solenoid electrical connector and remove the EVAP canister vent solenoid harness pushpin retainer. 10. Remove the EVAP canister assembly. 11. Disconnect the EVAP canister vent solenoid-to-dust separator fuel vapor hose. 12. Release the clips and remove the dust separator from the EVAP canister assembly. 13. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair Evaporative Emission Control Canister: Service and Repair EVAPORATIVE EMISSION CANISTER Evaporative Emission (EVAP) Canister Purge Valve Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Page 3189 EVAP Canister Assembly - Removal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Page 3190 EVAP Canister Assembly - Disassembly Exploded View Removal and Installation WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. NOTE: The evaporative emission (EVAP) canister assembly is located above the spare tire. Remove the spare tire. 4. Disconnect the fuel vapor tube quick connect coupling. 5. Disconnect the fuel vapor hose. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Page 3191 6. Remove the 2 front EVAP canister assembly bracket bolts. - To install, tighten to 13 Nm (10 lb-ft). 7. Remove the 2 outer rear EVAP canister assembly bracket bolts. - To install, tighten to 20 Nm (15 lb-ft). 8. Remove the 2 inner rear EVAP canister assembly bracket bolts. - To install, tighten to 13 Nm (10 lb-ft). 9. Lower the EVAP canister assembly down slightly to disconnect the EVAP canister vent solenoid electrical connector and remove the EVAP canister vent solenoid harness pushpin retainer. 10. Remove the EVAP canister assembly. 11. Remove the EVAP canister heat shield. 12. Disconnect the EVAP canister-to-EVAP filter assembly tube fuel vapor hose. 13. Remove the EVAP canister from the EVAP assembly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Page 3192 14. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair Evaporative Emissions Hose: Service and Repair FUEL VAPOR TUBE ASSEMBLY Evaporative Emission (EVAP) Canister Purge Valve Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Page 3196 EVAP Canister Assembly - Removal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Page 3197 EVAP Canister Assembly - Disassembly Exploded View Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Page 3198 Removal and Installation WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. 1. Remove the fuel tank. 2. Disconnect the 2 fuel vapor tube assembly-to-fuel pump module quick connect couplings. 3. Remove the fuel vapor tube assembly. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Description and Operation Leak Detection Solenoid: Description and Operation CANISTER VENT (CV) SOLENOID Typical Canister Vent (CV) Solenoid During the evaporative emissions (EVAP) leak check monitor, the CV solenoid seals the EVAP canister from the atmospheric pressure. This allows the EVAP canister purge valve to obtain the target vacuum in the fuel tank during the EVAP leak check monitor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 3205 C450 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 3206 Leak Detection Valve: Service and Repair EVAPORATIVE EMISSION CANISTER VENT SOLENOID Evaporative Emission (EVAP) Canister Purge Valve Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 3207 EVAP Canister Assembly - Removal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 3208 EVAP Canister Assembly - Disassembly Exploded View Removal and Installation WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. NOTE: The evaporative emission (EVAP) canister assembly is located above the spare tire. Remove the spare tire. 4. Disconnect the fuel vapor tube quick connect coupling. 5. Disconnect the fuel vapor hose. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 3209 6. Remove the 2 front EVAP canister assembly bracket bolts. - To install, tighten to 13 Nm (10 lb-ft). 7. Remove the 2 outer rear EVAP canister assembly bracket bolts. - To install, tighten to 20 Nm (15 lb-ft). 8. Remove the 2 inner rear EVAP canister assembly bracket bolts. - To install, tighten to 13 Nm (10 lb-ft). 9. Lower the EVAP canister assembly down slightly to disconnect the EVAP canister vent solenoid electrical connector and remove the EVAP canister vent solenoid harness pushpin retainer. 10. Remove the EVAP canister assembly. 11. Remove the EVAP canister heat shield. 12. Disconnect the EVAP canister-to-EVAP filter assembly tube fuel vapor hose. 13. Remove the EVAP canister vent solenoid and EVAP filter assembly tube from the EVAP assembly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 3210 14. Disconnect the EVAP canister vent solenoid-to-dust separator fuel vapor hose. 15. Separate the EVAP canister vent solenoid from the EVAP filter assembly tube. 16. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Module > Component Information > Locations EGR Control Module: Locations View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Module > Component Information > Locations > Page 3215 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Module > Component Information > Locations > Page 3216 C1450 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Service and Repair EGR Control Solenoid: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal 1. Disconnect the EGR system module electrical connector. 2. Disconnect the EGR system module vacuum connector. 3. Disconnect the exhaust manifold-to-EGR system module tube from the EGR system module. 4. Remove the bolts, the EGR system module and the gasket. Discard the gasket. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old gasket. Clean the EGR system module gasket mating surfaces. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Service and Repair > Page 3220 2. Install a new gasket with the raised circle facing the throttle body (TB) adapter. 3. Position the EGR system module and install the bolts. - Tighten to 25 Nm (18 lb-ft). 4. Connect the exhaust manifold-to-EGR system module tube the EGR system module. - Tighten to 40 Nm (30 lb-ft). 5. Connect the EGR system module vacuum connector. 6. Connect the EGR system module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Description and Operation EGR Electronic Vacuum Regulator Solenoid: Description and Operation EXHAUST GAS RECIRCULATION (EGR) VACUUM REGULATOR SOLENOID EGR Vacuum Regulator Solenoid Vacuum Output (IN-HG) EGR Vacuum Regulator Solenoid Data The EGR vacuum regulator solenoid is an electromagnetic device used to regulate the vacuum supply to the EGR valve. The solenoid contains a coil which magnetically controls the position of a disc to regulate the vacuum. As the duty cycle to the coil increases, the vacuum signal passed through the solenoid to the EGR valve also increases. Vacuum not directed to the EGR valve is vented through the solenoid vent to atmosphere. Note that at 0% duty cycle (no electrical signal applied), the EGR vacuum regulator solenoid allows some vacuum to pass, but not enough to open the EGR valve. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Description and Operation EGR Tube: Description and Operation EXHAUST GAS RECIRCULATION (EGR) ORIFICE TUBE ASSEMBLY EGR Orifice Tube Assembly The orifice tube assembly is a section of tubing connecting the exhaust system to the intake manifold. The assembly provides the flow path for the EGR to the intake manifold and also contains the metering orifice and 2 pressure pick-up tubes. The internal metering orifice creates a measurable pressure drop across it as the EGR valve opens and closes. This pressure differential across the orifice is picked up by the differential pressure feedback EGR sensor which provides feedback to the PCM. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Description and Operation > Page 3227 EGR Tube: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE TUBE Exploded View Removal and Installation 1. Detach the exhaust manifold-to-EGR system module tube from the exhaust manifold and the EGR system module and remove the tube. - To install, hand start the EGR system module tube fitting at the EGR system module side first, and then the exhaust manifold side. - To install, tighten to 40 Nm (30 lb-ft). 2. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation EGR Valve: Description and Operation Electric Exhaust Gas Recirculation (EEGR) Valve EEGR Motor/Valve Assembly Depending on the application, the EEGR valve is a water cooled or an air cooled motor/valve assembly. The motor is commanded to move in 52 discrete steps as it acts directly on the EEGR valve. The position of the valve determines the rate of EGR. The built-in spring works to close the valve (against the motor opening force). Exhaust Gas Recirculation (EGR) System Module (ESM) ESM Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Page 3231 The ESM is an integrated differential pressure feedback EGR system that functions in the same manner as a conventional differential pressure feedback EGR system. The various system components have been integrated into a single component called the ESM. The flange of the valve portion of the ESM bolts directly to the intake manifold with a metal gasket that forms the metering orifice. This arrangement increases system reliability, response time, and system precision. By relocating the EGR orifice from the exhaust to the intake side of the EGR valve, the downstream pressure signal measures manifold absolute pressure (MAP). This MAP signal is used for EGR correction and inferred barometric pressure (BARO) at key on. The system provides the powertrain control module (PCM) with a differential pressure feedback EGR signal, identical to a traditional differential pressure feedback EGR system. Exhaust Gas Recirculation (EGR) Valve Typical EGR Valve EGR Flowrate The EGR valve in the differential pressure feedback EGR system is a conventional, vacuum-actuated. The valve increases or decreases the flow of EGR. As vacuum applied to the EGR valve diaphragm overcomes the spring force, the valve begins to open. As the vacuum signal weakens, at 5.4 kPa (1.6 in-Hg) or less, the spring force closes the valve. The EGR valve is fully open at about 15 kPa (4.5 in-Hg). Since EGR flow requirement varies greatly, providing repair specifications on flow rate is impractical. The on board diagnostic (OBD) system monitors the EGR valve function and triggers a diagnostic trouble code (DTC) if the test criteria is not met. The EGR valve flow rate is not measured directly as part of the diagnostic procedures. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Page 3232 EGR Valve: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal 1. Disconnect the EGR system module electrical connector. 2. Disconnect the EGR system module vacuum connector. 3. Disconnect the exhaust manifold-to-EGR system module tube from the EGR system module. 4. Remove the bolts, the EGR system module and the gasket. Discard the gasket. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old gasket. Clean the EGR system module gasket mating surfaces. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Page 3233 2. Install a new gasket with the raised circle facing the throttle body (TB) adapter. 3. Position the EGR system module and install the bolts. - Tighten to 25 Nm (18 lb-ft). 4. Connect the exhaust manifold-to-EGR system module tube the EGR system module. - Tighten to 40 Nm (30 lb-ft). 5. Connect the EGR system module vacuum connector. 6. Connect the EGR system module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback EGR sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3237 The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3238 Pressure Feedback Exhaust Sensor: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal 1. Disconnect the EGR system module electrical connector. 2. Disconnect the EGR system module vacuum connector. 3. Disconnect the exhaust manifold-to-EGR system module tube from the EGR system module. 4. Remove the bolts, the EGR system module and the gasket. Discard the gasket. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old gasket. Clean the EGR system module gasket mating surfaces. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3239 2. Install a new gasket with the raised circle facing the throttle body (TB) adapter. 3. Position the EGR system module and install the bolts. - Tighten to 25 Nm (18 lb-ft). 4. Connect the exhaust manifold-to-EGR system module tube the EGR system module. - Tighten to 40 Nm (30 lb-ft). 5. Connect the EGR system module vacuum connector. 6. Connect the EGR system module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Diagrams > Heated Positive Crankcase Ventilation (PCV) Valve C190 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Diagrams > Heated Positive Crankcase Ventilation (PCV) Valve > Page 3245 C1546 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Diagrams > Page 3246 Positive Crankcase Ventilation Valve: Service and Repair POSITIVE CRANKCASE VENTILATION (PCV) VALVE Removal and Installation 1. Disconnect the PCV tube quick connect coupling. 2. Disconnect the PCV valve electrical connector. 3. Rotate the PCV valve counterclockwise and remove the PCV valve. - Discard the PCV valve. 4. To install, reverse the removal procedure. - Install a new PCV valve. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations EGR Control Module: Locations View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations > Page 3251 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations > Page 3252 C1450 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback EGR sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3257 The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3258 Pressure Feedback Exhaust Sensor: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal 1. Disconnect the EGR system module electrical connector. 2. Disconnect the EGR system module vacuum connector. 3. Disconnect the exhaust manifold-to-EGR system module tube from the EGR system module. 4. Remove the bolts, the EGR system module and the gasket. Discard the gasket. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old gasket. Clean the EGR system module gasket mating surfaces. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3259 2. Install a new gasket with the raised circle facing the throttle body (TB) adapter. 3. Position the EGR system module and install the bolts. - Tighten to 25 Nm (18 lb-ft). 4. Connect the exhaust manifold-to-EGR system module tube the EGR system module. - Tighten to 40 Nm (30 lb-ft). 5. Connect the EGR system module vacuum connector. 6. Connect the EGR system module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Item....................................................................................................................................................... ..............................................................Specification Fuel Pressure Engine running..................................................................................................................................... ..............................................193-310 kPa (28-45 psi) Key ON, engine OFF (KOEO)......................... ..................................................................................................................................240-310 kPa (35-45 psi) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3264 Fuel Pressure: Testing and Inspection FUEL SYSTEM PRESSURE TEST Special Tool(s) Special Tool(s) WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. 1. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. 2. NOTE: 5.4L shown, 4.6L and 4.2L similar. Install the special tools in line between the fuel supply tube and fuel rail. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3265 3. NOTE: The electrical connector was disconnected during fuel system pressure release. Connect the electrical connector. 4. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 5. Test the fuel system pressure to make sure it is within the specified range. 6. NOTE: - 5.4L shown, 4.6L and 4.2L similar. - Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Upon completion of the fuel system pressure test, open the drain valve on the special tool and relieve the fuel system pressure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE Special Tool(s) Special Tool(s) 1. NOTE: The splash shield is located on the LH frame rail under the driver side door. Disconnect the splash shield and position aside. 2. Disconnect the electrical connector. 3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition switch to the OFF position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Page 3269 6. When fuel system service is complete, connect the electrical connector. 7. Reposition the splash shield and install a new pushpin. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Install the scan tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON. Select the appropriate vehicle and engine qualifier. Clear all DTCs and carry out a PCM reset. 10. Start the vehicle and check the fuel system for leaks. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Typical Diagnostic Reference Value Measured/PID Values 665 RPM .......................................................................................................... ..................................................................................................... Hot Idle Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Torque Specifications Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal - Fixed Accelerator Pedal: Service and Repair Accelerator Pedal - Fixed ACCELERATOR PEDAL - FIXED Removal and Installation 1. Disconnect the accelerator pedal electrical connector. 2. Remove the 3 accelerator pedal assembly bolts and the accelerator pedal assembly. - To install, tighten to 25 Nm (18 lb-ft). 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal - Fixed > Page 3278 Accelerator Pedal: Service and Repair Accelerator Pedal - Adjustable ACCELERATOR PEDAL - ADJUSTABLE Removal and Installation NOTE: The brake pedal and the accelerator pedal must be in the same position when installing a new cable or a new accelerator pedal. The pedals must be all the way forward or all the way rearward. 1. Disconnect the accelerator pedal electrical connector. 2. Disconnect the accelerator pedal assembly drive cable. 3. Remove the 3 accelerator pedal assembly bolts and the accelerator pedal assembly. - To install, tighten to 25 Nm (18 lb-ft). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3282 C2251 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3283 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor 2-Track APP Sensor There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are 2 reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 3-Track APP Sensor Typical 3-Track APP Sensor There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APP2 and APP3, both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair AIR CLEANER ELEMENT Exploded View Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. Detach the electrical connector retainer. 2. Loosen the clamp and disconnect the air cleaner outlet pipe from the air cleaner cover. - To install, tighten to 4 Nm (35 lb-in). 3. Open the clamp and detach the air cleaner cover from the air cleaner tray. 4. Remove the air cleaner element. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3291 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3292 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3293 C1454 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3294 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3295 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3296 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Open the clamp on the air cleaner and separate the tray from the cover. 2. Disconnect the mass air flow (MAF) sensor electrical connector and detach the connector retainer. 3. Remove the grommet from the air cleaner cover and slide it down the electrical harness. 4. Pull the air cleaner inner cover and MAF sensor out of the air cleaner cover. 5. Disconnect the MAF sensor electrical connector and remove the inner cover and MAF sensor assembly. 6. Remove the bolts and the MAF sensor. - To install, tighten to 2 Nm (18 lb-in). 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator > Component Information > Description and Operation Fuel Filler Cap Warning Indicator: Description and Operation CHECK FUEL CAP INDICATOR The check fuel cap indicator is a communications network message sent by the PCM. The PCM sends the message to illuminate the lamp when the strategy determines there is a concern in the EVAP system due to the fuel filler cap or capless fuel tank filler pipe not being sealed correctly. This would be detected by the inability to pull vacuum in the fuel tank, after a fueling event. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE Special Tool(s) Special Tool(s) 1. NOTE: The splash shield is located on the LH frame rail under the driver side door. Disconnect the splash shield and position aside. 2. Disconnect the electrical connector. 3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition switch to the OFF position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 3304 6. When fuel system service is complete, connect the electrical connector. 7. Reposition the splash shield and install a new pushpin. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Install the scan tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON. Select the appropriate vehicle and engine qualifier. Clear all DTCs and carry out a PCM reset. 10. Start the vehicle and check the fuel system for leaks. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Fuel Injector Resistance ...................................................................................................................... ............................................................. 11 - 18 Ohms Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 3309 Fuel Injector: Pressure, Vacuum and Temperature Specifications Fuel Injector Flow and Leakage ..................................................................... Refer to Pinpoint Test HC12 and HC13 at Computers and Control Systems. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 C181 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3312 C182 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3313 C183 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3314 C184 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3315 Fuel Injector: Diagrams C181 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3316 C182 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3317 C183 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3318 C184 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3319 C185 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3320 C186 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3321 C187 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3322 C188 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3323 Fuel Injector: Description and Operation FUEL INJECTORS Typical Fuel Injector CAUTION: Do not apply battery positive voltage (B+) directly to the fuel injector electrical connector terminals. The solenoids may be damaged internally in a matter of seconds. The fuel injector is a solenoid-operated valve that meters fuel flow to the engine. The fuel injector is opened and closed a constant number of times per crankshaft revolution. The amount of fuel is controlled by the length of time the fuel injector is held open. The fuel injector is normally closed, and is operated by a 12-volt source from either the electronic engine control (EEC) power relay or fuel pump relay. The ground signal is controlled by the PCM. The injector is the deposit resistant injector (DRI) type and does not have to be cleaned. However, it can be flow checked and, if found outside of specification, a new fuel injector should be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3324 Fuel Injector: Service and Repair FUEL INJECTORS Part 1 Part 2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3325 Exploded View Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Remove the fuel rail. 2. Remove the 8 fuel injectors. 3. NOTE: - Install new O-ring seals on the fuel injectors. - Lubricate the new fuel injector O-ring seals with clean engine oil prior to installing the fuel injectors. Remove and discard the 8 lower fuel injector O-ring seals. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings Fuel Line Coupler: Service and Repair Spring Lock Couplings SPRING LOCK COUPLINGS Special Tool(s) Special Tool(s) Disconnect - Type I WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. CAUTION: - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes. - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the fuel tube safety clip. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3330 4. Install the special tool. 5. Close and push the special tool into the open side of the cage. 6. Separate the spring lock coupling. Connect - Type I 1. Inspect and clean both spring lock coupling ends. Install new O-ring seals and garter springs, if necessary. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3331 2. NOTE: Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. Apply clean engine oil to O-ring seals. Fit the male end into the female end and push until the garter spring snaps over the flared end of the female end. 3. Make sure the spring lock coupling is engaged by pulling on the tube. 4. Install the safety clip. Disconnect - Type II WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. CAUTION: - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes. - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3332 1. Release the fuel pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel tube safety clip from the male end. 4. Install the special tool and press it into the spring lock coupling. 5. Separate the spring lock coupling. Connect - Type II 1. Inspect and clean both spring lock coupling ends. 2. NOTE: - Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. - Lubricate the spring lock coupling with clean engine oil to ease assembly. Align and push the fuel tube spring lock coupling until a click is heard. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3333 3. Pull on the spring lock coupling to make sure it is fully seated, then install the fuel tube safety clip on the male end. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3334 Fuel Line Coupler: Service and Repair Vapor Tube Fittings VAPOR TUBE FITTINGS Disconnect WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. CAUTION: - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. - Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation. 1. Disconnect the battery ground cable. 2. Disconnect the vapor tube fitting. - Push the vapor tube fitting toward the tube or fitting to release pressure. - Press the vapor tube fitting button and pull the fuel tube to disconnect. Connect 1. Inspect the vapor tube fitting and the tube for damage. Remove any dirt or obstructions. 2. NOTE: - Make sure the vapor tube fitting clicks into place when installing the tube. To make sure that the vapor tube fitting is fully seated, pull on the tube. - Apply clean engine oil to the end of the tube or fitting before connecting. Connect the vapor tube fitting. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3335 Fuel Line Coupler: Service and Repair Quick Connect Coupling QUICK CONNECT COUPLING Disconnect - Type I WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. CAUTION: - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes. - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. - Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation. 1. If servicing a liquid fuel tube, release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Press the tab corners to release the locking tab. 4. Pull the locking tab to the release position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3336 5. Disconnect the quick connect coupling. - Push the quick connect coupling toward the tube to release pressure. - Press the tab corners to release the quick connect coupling. - Disconnect the quick connect coupling. Connect - Type I 1. Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions. 2. NOTE: - Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. - Apply clean engine oil to the end of the tube or quick connect coupling before connecting. Connect the tube into the quick connect coupling. 3. Press the locking tab down into the locked position. Disconnect - Type II WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3337 - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. CAUTION: - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes. - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. - Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation. 1. If servicing a liquid fuel tube, release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel tube quick connect coupling. - Press the fuel tube quick connect coupling button and pull the fuel tube to disconnect. Connect - Type II 1. Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions. 2. NOTE: - Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. - Apply clean engine oil to O-ring seals. Install the quick connect coupling onto the tube until it is fully seated. Disconnect - Type III WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. CAUTION: - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip may occur. Apply clean engine oil to Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3338 the end of the tube before inserting the tube into the connector. - Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation. 1. Release the locking tab on the quick connect coupling. 2. Separate the quick connect coupling from the fitting. Connect - Type III 1. Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions. 2. NOTE: Apply clean engine oil to O-ring seals. Release the locking tab and install the quick connect coupling onto the fitting. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3339 3. NOTE: Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. Position the locking tab into the latched position. Disconnect - Type IV WARNING: - When working on or near the evaporative emission (EVAP) system, disconnect the battery ground cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious personal injury. - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. CAUTION: - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes. - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. - Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation. 1. If servicing a liquid fuel tube, release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel tube quick connect coupling. - Press the 2 fuel tube quick connect coupling buttons and pull the fuel tube to disconnect. Connect - Type IV 1. Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3340 2. NOTE: - Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. - Apply clean engine oil to O-ring seals. Install the quick connect coupling onto the tube until it is fully seated. Disconnect - Type V WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. CAUTION: - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage can occur. Always install blanking plugs to any open orifices or tubes. - Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 1. If servicing a liquid fuel tube, release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Depress the legs of the retainer clip and position the clip to the outward position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3341 4. Disconnect the quick connect coupling from the fuel tube. Connect - Type V 1. Inspect and clean both quick connect coupling ends. 2. NOTE: Apply clean engine oil to the end of the tube and the quick connect coupling O-ring seals. Install the quick connect coupling onto the fuel tube until fully seated. 3. NOTE: Make sure the retainer clip is fully seated and locked onto the fuel tube by pulling on the quick connect coupling. Press the retainer clip into the quick connect coupling body until flush and the legs are locked in place. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Fuel Pressure Sensor/Switch: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3345 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3346 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3347 Fuel Pressure Sensor/Switch: Diagrams C173 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3348 C1475 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3349 Fuel Pressure Sensor/Switch: Description and Operation FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3350 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the fuel pressure and temperature sensor electrical connector. 3. Disconnect the fuel pressure and temperature sensor vacuum connector. 4. Remove the bolts and the fuel pressure and temperature sensor. - To install, tighten to 4 Nm (35 lb-in). 5. Remove and discard the O-ring seal. - Install a new O-ring seal and lubricate with clean engine oil prior to installation. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Description and Operation Fuel Pressure Pulsation Damper: Description and Operation FUEL RAIL PULSE DAMPER Typical Fuel Rail Pulse Damper The fuel rail pulse damper is located on the fuel rail and reduces the fuel system noise caused by the pulsing of the fuel injectors. The vacuum port located on the damper is connected to manifold vacuum to avoid fuel spillage if the pulse damper diaphragm ruptures. The fuel rail pulse damper should not be confused with a fuel pressure regulator; it does not regulate the fuel rail pressure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Item....................................................................................................................................................... ..............................................................Specification Fuel Pressure Engine running..................................................................................................................................... ..............................................193-310 kPa (28-45 psi) Key ON, engine OFF (KOEO)......................... ..................................................................................................................................240-310 kPa (35-45 psi) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3358 Fuel Pressure: Testing and Inspection FUEL SYSTEM PRESSURE TEST Special Tool(s) Special Tool(s) WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. 1. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. 2. NOTE: 5.4L shown, 4.6L and 4.2L similar. Install the special tools in line between the fuel supply tube and fuel rail. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3359 3. NOTE: The electrical connector was disconnected during fuel system pressure release. Connect the electrical connector. 4. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 5. Test the fuel system pressure to make sure it is within the specified range. 6. NOTE: - 5.4L shown, 4.6L and 4.2L similar. - Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Upon completion of the fuel system pressure test, open the drain valve on the special tool and relieve the fuel system pressure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Locations View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Locations > Page 3363 C433 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Locations > Page 3364 Fuel Pump Control Unit: Service and Repair FUEL PUMP DRIVER MODULE (FPDM) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The fuel pump driver module (FPDM) is located above the spare tire. Disconnect the FPDM electrical connector. 3. Remove the FPDM bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair Fuel Rail: Service and Repair FUEL RAIL Part 1 Part 2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Page 3371 Exploded View Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Disconnect the fuel hose spring lock coupling. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the air cleaner outlet pipe. 4. Remove the EGR system module tube. - To install, tighten to 40 Nm (30 lb-ft). 5. Disconnect the EGR system module electrical connector. 6. Disconnect the quick connect couplings and remove the PCV tube. 7. Disconnect the electronic throttle control electrical connector. 8. Disconnect the fuel rail pressure and temperature sensor electrical connector. 9. Disconnect the fuel rail pressure and temperature sensor vacuum connector. 10. Disconnect the 8 fuel injector electrical connectors. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Page 3372 11. Disconnect the vacuum and coolant hose and plug the coolant hose. 12. Disconnect the brake booster vacuum hose and the evaporative emissions (EVAP) hose quick connect coupling. 13. Remove the 4 fuel rail stud bolts. - To install, tighten to 10 Nm (89 lb-in). 14. NOTE: When removing the fuel rail, leave the fuel injectors in the intake manifold. This will make removal of the fuel rail easier. Separate the fuel rail from the fuel injectors and remove the fuel rail. 15. NOTE: - Install new fuel injector-to-fuel rail O-ring seals on the fuel injectors. - Lubricate the new fuel injector-to-fuel rail O-ring seals with clean engine oil prior to installing the fuel rail. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair Fuel Supply Line: Service and Repair FUEL LINES Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 3376 Part 2 Exploded View Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - Remove the fuel filler cap slowly. The fuel system may be under pressure. If the fuel filler cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing the fuel filler cap. Otherwise, fuel may spray out. Failure to follow these instructions may result in serious personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Release the fuel system pressure. 3. Disconnect the battery ground cable. 4. Disconnect the fuel filter outlet fuel tube spring lock coupling. 5. Disconnect the fuel filter bracket outlet vapor tube spring lock coupling. 6. Disconnect the fuel rail spring lock coupling. 7. Disconnect the evaporative emission (EVAP) canister purge valve vapor tube quick connect coupling. 8. Release the vapor and fuel tubes from the support bracket. 9. Remove the fuel tube assembly support bracket nut. - To install, tighten to 25 Nm (18 lb-ft). 10. Remove the fuel tube assembly support bracket and remove the fuel and vapor tube assembly. 11. To install, reverse the removal procedure. - If a tie strap was removed, reinstall a new tie strap in the same location. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair Fuel Filler Hose: Service and Repair FUEL TANK FILLER PIPE Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. - Remove the fuel filler cap slowly. The fuel system may be under pressure. If the fuel filler cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing the fuel filler cap. Otherwise, fuel may spray out. Failure to follow these instructions may result in serious personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the fuel tank filler cap. 4. Disconnect the fuel tank filler pipe from the fuel tank. 5. Disconnect the fuel tank filler pipe vent tube quick connect coupling. 6. Remove the 3 screws from the fuel tank filler pipe and remove the fuel tank filler pipe. 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-2-9 > Feb > 08 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 Fuel Gauge Sender: Customer Interest Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 TSB 08-2-9 02/04/08 ERRATIC FUEL GAUGE OPERATION - MIL ON - DTCS P0460/P0463 OR INSTRUMENT CLUSTER MODULE DTC B1201 - VEHICLES BUILT BEFORE 12/3/2007 FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT vehicles, built before 12/3/2007, may exhibit erratic fuel gauge operation or illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P0460 or P0463, and/or Instrument Cluster Module DTC B1201. This may be caused by sulphur contamination in the fuel causing an open or high resistance in the fuel level sender. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Install a new fuel level sender following the service procedure instruction sheet provided in the fuel sender kit. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 080209A 2004-2008 F-150, 1.9 Hrs. 2006-2008 Mark LT: Install New Fuel Level Sender, Includes Time To Remove Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-2-9 > Feb > 08 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 > Page 3389 And Install Fuel Tank (Do Not Use With 9002A, 9002A4, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-2-9 > Feb > 08 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 TSB 08-2-9 02/04/08 ERRATIC FUEL GAUGE OPERATION - MIL ON - DTCS P0460/P0463 OR INSTRUMENT CLUSTER MODULE DTC B1201 - VEHICLES BUILT BEFORE 12/3/2007 FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT vehicles, built before 12/3/2007, may exhibit erratic fuel gauge operation or illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P0460 or P0463, and/or Instrument Cluster Module DTC B1201. This may be caused by sulphur contamination in the fuel causing an open or high resistance in the fuel level sender. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Install a new fuel level sender following the service procedure instruction sheet provided in the fuel sender kit. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 080209A 2004-2008 F-150, 1.9 Hrs. 2006-2008 Mark LT: Install New Fuel Level Sender, Includes Time To Remove Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-2-9 > Feb > 08 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 > Page 3395 And Install Fuel Tank (Do Not Use With 9002A, 9002A4, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 3396 View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 3397 Fuel Gauge Sender: Diagrams C4074 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 3398 C4330 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 3399 Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 3400 The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Fuel Pump (FP) Module and Reservoir The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module Fuel Gauge Sender: Service and Repair Fuel Pump Module FUEL PUMP MODULE Special Tool(s) Special Tool(s) Removal WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 3403 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the fuel tank. 3. Using soapy water, clean a minimum of 76 mm (3 in) surface area around the fuel pump module. 4. Disconnect the fuel supply and fuel vapor tube assembly quick connect couplings at the fuel pump module and remove the fuel supply and fuel vapor tube assembly from the fuel tank. 5. Using the special tool, remove the fuel pump module locking ring. 6. Lift the fuel pump module out of the fuel tank enough to disconnect the internal fuel tank grade vent valves-to-fuel pump quick connect coupling. 7. CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter. Remove the fuel pump module. 8. Remove and discard the fuel pump module O-ring seal. Installation 1. NOTE: Lubricate the new fuel pump module O-ring seal with clean engine oil prior to installation. Install a new fuel pump module O-ring seal. 2. CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter. Install the fuel pump module into the fuel tank enough to connect the internal fuel tank grade vent valves-to-fuel pump quick connect coupling. 3. Install the fuel pump module the rest of the way into the fuel tank. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 3404 4. Using the special tool, install the fuel pump module locking ring. 5. NOTE: - The fuel pump module does not come equipped with a fuel pump module cover from the factory. The fuel pump module cover is only installed after service to the fuel pump module is performed. - Before installing the fuel pump module cover, make sure it fits around all fuel and vapor ports and electrical connectors and allows enough clearance to install the fuel and vapor tube assembly and the fuel pump module electrical connector. - Make sure a minimum of 76 mm (3 in) surface area is properly cleaned of all gas, oil and foreign material before installing the fuel pump module cover. Install a fuel pump module cover over the fuel pump module and locking ring. 6. Install the fuel supply and fuel vapor tube assembly onto the fuel tank and connect the fuel supply and fuel vapor tube assembly quick connect couplings at the fuel pump module. 7. Install the fuel tank. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 3405 Fuel Gauge Sender: Service and Repair Fuel Level Sender FUEL LEVEL SENDER Removal WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. 1. Remove the fuel pump module. 2. NOTE: Note the routing of the fuel level sender wire for installation. Unwrap the fuel level sender wire from the rest of the fuel pump module wire harness. 3. Remove the heat shrink tube covering the electrical connector. 4. Disconnect the electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 3406 5. NOTE: Gasoline shown, flexible fuel similar. Remove the screw and lift up to remove the fuel level sender. Installation All vehicles 1. Route the fuel level sender wire through the center of the fuel pump module. Gasoline vehicles 2. NOTE: - Both fuel level sender wires must be routed behind the metal fuel level sender plate. - The grounding eyelet must be on the front side of the fuel level sender. Hook the fuel level sender on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. Flexible fuel vehicles Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 3407 3. NOTE: - One fuel level sender wire routes behind the fuel level sender and one routes along the left side of the fuel level sender. - The grounding eyelet must be on the front side of the fuel level sender. Hook the fuel level sender on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. Clip the wire into the clip on the fuel pump module. All vehicles 4. Slide the heat shrink tube onto the wire harness and connect the electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, heat the heat shrink tube. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 3408 6. Wrap the fuel level sender wire around the fuel pump module wire harness to make sure the wire will not interfere with the movement of the fuel gauge sending unit float arm. 7. Install the fuel pump module. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 3412 Fuel Tank Unit: Diagrams C4074 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 3413 C4330 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 3414 Fuel Tank Unit: Description and Operation Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 3415 The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Fuel Pump (FP) Module and Reservoir The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Temperature Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3419 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3420 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3421 Fuel Temperature Sensor: Diagrams C173 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3422 C1475 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3423 Fuel Temperature Sensor: Description and Operation FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3424 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the fuel pressure and temperature sensor electrical connector. 3. Disconnect the fuel pressure and temperature sensor vacuum connector. 4. Remove the bolts and the fuel pressure and temperature sensor. - To install, tighten to 4 Nm (35 lb-in). 5. Remove and discard the O-ring seal. - Install a new O-ring seal and lubricate with clean engine oil prior to installation. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation Idle Speed/Throttle Actuator - Electronic: Description and Operation IDLE AIR CONTROL (IAC) VALVE NOTE: The IAC valve assembly is not adjustable and cannot be cleaned, also some IAC valves are normally open and others are normally closed. Some IAC valves require engine vacuum to operate. The IAC valve assembly controls the engine idle speed and provides a dashpot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine RPM and increases or decreases the IAC duty cycle in order to achieve the desired RPM. The PCM uses the IAC valve assembly to control: - no touch start - cold engine fast idle for rapid warm-up - idle (corrects for engine load) - stumble or stalling on deceleration (provides a dashpot function) - over-temperature idle boost Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-18 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3431 C282 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3432 Inertia Fuel Shutoff Switch: Description and Operation INERTIA FUEL SHUTOFF (IFS) SWITCH Typical Inertia Fuel Shutoff (IFS) Switch The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shutoff the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner's Literature, Roadside Emergencies for the location of the IFS switch. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3433 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. Remove the RH cowl side trim panel. 2. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 3. Remove the 2 IFS bolts and the IFS switch. - To install, tighten to 2 Nm (18 lb-in). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair Intake Air Duct: Service and Repair AIR CLEANER OUTLET PIPE Exploded View Removal and Installation 1. Disconnect the crankcase breather hose from the air cleaner outlet pipe. 2. Loosen the clamps at the throttle body (TB) and the air cleaner cover. Remove the air cleaner outlet pipe. - To install, tighten to 4 Nm (35 lb-in). 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3440 Main Relay (Computer/Fuel System): Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 3445 C433 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 3446 Fuel Pump Control Unit: Service and Repair FUEL PUMP DRIVER MODULE (FPDM) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The fuel pump driver module (FPDM) is located above the spare tire. Disconnect the FPDM electrical connector. 3. Remove the FPDM bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3453 Main Relay (Computer/Fuel System): Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3458 C2251 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3459 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor 2-Track APP Sensor There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are 2 reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 3-Track APP Sensor Typical 3-Track APP Sensor There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APP2 and APP3, both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3463 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3464 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3465 C1454 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3466 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3467 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3468 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Open the clamp on the air cleaner and separate the tray from the cover. 2. Disconnect the mass air flow (MAF) sensor electrical connector and detach the connector retainer. 3. Remove the grommet from the air cleaner cover and slide it down the electrical harness. 4. Pull the air cleaner inner cover and MAF sensor out of the air cleaner cover. 5. Disconnect the MAF sensor electrical connector and remove the inner cover and MAF sensor assembly. 6. Remove the bolts and the MAF sensor. - To install, tighten to 2 Nm (18 lb-in). 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Fuel Pressure Sensor/Switch: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3472 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3473 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3474 Fuel Pressure Sensor/Switch: Diagrams C173 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3475 C1475 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3476 Fuel Pressure Sensor/Switch: Description and Operation FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3477 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the fuel pressure and temperature sensor electrical connector. 3. Disconnect the fuel pressure and temperature sensor vacuum connector. 4. Remove the bolts and the fuel pressure and temperature sensor. - To install, tighten to 4 Nm (35 lb-in). 5. Remove and discard the O-ring seal. - Install a new O-ring seal and lubricate with clean engine oil prior to installation. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Temperature Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3481 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3482 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3483 Fuel Temperature Sensor: Diagrams C173 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3484 C1475 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3485 Fuel Temperature Sensor: Description and Operation FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3486 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the fuel pressure and temperature sensor electrical connector. 3. Disconnect the fuel pressure and temperature sensor vacuum connector. 4. Remove the bolts and the fuel pressure and temperature sensor. - To install, tighten to 4 Nm (35 lb-in). 5. Remove and discard the O-ring seal. - Install a new O-ring seal and lubricate with clean engine oil prior to installation. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-18 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3490 C282 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3491 Inertia Fuel Shutoff Switch: Description and Operation INERTIA FUEL SHUTOFF (IFS) SWITCH Typical Inertia Fuel Shutoff (IFS) Switch The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shutoff the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner's Literature, Roadside Emergencies for the location of the IFS switch. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3492 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. Remove the RH cowl side trim panel. 2. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 3. Remove the 2 IFS bolts and the IFS switch. - To install, tighten to 2 Nm (18 lb-in). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3496 C189 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3497 Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The 2 ETB throttle position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. Throttle Position (TP) Sensor Typical TP Sensor The TP sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a 3-blade electrical connector that may be gold plated. The gold plating increases the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating conditions are: closed throttle (includes idle or deceleration) - part throttle (includes cruise or moderate acceleration) - wide open throttle (includes maximum acceleration or de-choke on crank) - throttle angle rate Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair Throttle Body: Service and Repair THROTTLE BODY Removal and Installation CAUTION: The throttle body (TB) must be removed from the vehicle to be cleaned. Do not hold the throttle plate open with any object that could scratch the bore or plate while servicing or cleaning the TB. 1. Remove the air cleaner outlet pipe. 2. Disconnect the electronic throttle control electrical connector. 3. Remove the throttle body (TB) bolts and discard the TB gasket. - Install a new TB gasket. - To install, tighten to 9 Nm (80 lb-in). - Tighten an additional 90 degrees (1/4 turn). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3504 C189 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3505 Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). The 2 ETB throttle position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. Throttle Position (TP) Sensor Typical TP Sensor The TP sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a 3-blade electrical connector that may be gold plated. The gold plating increases the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating conditions are: closed throttle (includes idle or deceleration) - part throttle (includes cruise or moderate acceleration) - wide open throttle (includes maximum acceleration or de-choke on crank) - throttle angle rate Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Actuator > Component Information > Diagrams C1442 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Actuator > Component Information > Diagrams > Page 3510 Variable Induction Control Actuator: Description and Operation INTAKE MANIFOLD TUNING VALVE (IMTV) WARNING: Substantial opening and closing torque is applied by this system. To prevent injury, be careful to keep fingers away from lever mechanisms when actuated. The IMTV is a motorized actuated unit mounted directly to the intake manifold. The IMTV actuator controls a shutter device attached to the actuator shaft. There is no monitor input to the PCM with this system to indicate shutter position. The motorized IMTV unit is not energized below approximately 2,600 RPM. The shutter is in the closed position not allowing airflow blend to occur in the intake manifold. The motorized unit is energized above approximately 2,600 RPM. The motorized unit is commanded on by the PCM initially at a 100 percent duty cycle to move the shutter to the open position, and then falling to approximately 50 percent to continue to hold the shutter open. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications Firing order........................................................................................................................................... ...........................................................1-3-7-2-6-5-4-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > System Information > Specifications Ignition Timing: Specifications Item....................................................................................................................................................... ..............................................................Specification Base timing........................................................................................................................................... ............................10° before top dead center (BTDC) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3522 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3523 Camshaft Position Sensor: Locations Camshaft Position Sensor View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3524 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor Camshaft Position Sensor: Diagrams Camshaft Position Sensor C180 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3527 C1180 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3528 C1366 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3529 C1367 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3530 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil on plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3531 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the camshaft position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. - Lubricate the CMP sensor O-ring seal with clean engine oil prior to installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3535 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3536 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3537 C101 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3538 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3539 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Rotate the accessory drive belt clockwise and detach the accessory drive belt from the A/C compressor pulley. 3. Loosen the A/C compressor bolts enough to slide the A/C compressor down approximately 25 mm (1 in), to allow access to the crankshaft position (CKP) sensor. To install, tighten to 25 Nm (18 lb-ft). 4. Disconnect the CKP sensor electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3540 5. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 6. To install, reverse the removal procedure. - Lubricate the O-ring seal with clean engine oil prior to installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications Torque Specifications Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 C111 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3546 C112 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3547 C113 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3548 C114 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3549 Ignition Coil: Diagrams C111 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3550 C112 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3551 C113 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3552 C114 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3553 C115 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3554 C116 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3555 C117 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3556 C118 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3557 C1196 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3558 C174 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3559 C1544 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3560 C194 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3561 C1545 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3562 Ignition Coil: Description and Operation Coil On Plug (COP) Typical Coil On Plug (COP) The COP ignition operates similar to a standard coil pack ignition except each plug has one coil per plug. The COP has 3 different modes of operation: engine crank, engine running, and CMP failure mode effects management (FMEM). Coil Pack Typical Four-Tower Coil Pack Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3563 Typical Six-Tower Coil Pack The PCM provides a grounding switch for the coil primary circuit. When the switch is closed, voltage is applied to the coil primary circuit. This creates a magnetic field around the primary coil. The PCM opens the switch, causing the magnetic field to collapse, inducing the high voltage in the secondary coil windings and firing the spark plug. The spark plugs are paired so that as one spark plug fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil is fired the order is reversed. The next pair of spark plugs fire according to the engine firing order. Coil packs come in 4-tower, 6-tower horizontal and series 5 6-tower models. Two adjacent coil towers share a common coil and are called a matched pair. For 6-tower coil pack (6 cylinder) applications, the matched pairs are 1 and 5, 2 and 6, and 3 and 4. For 4-tower coil pack (4 cylinder) applications, the matched pairs are 1 and 4, and 2 and 3. When the coil is fired by the PCM, spark is delivered through the matched pair towers to their respective spark plugs. The spark plugs are fired simultaneously and are paired so that as one fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil is fired, the situation is reversed. The next pair of spark plugs fire according to the engine firing order. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3564 Ignition Coil: Service and Repair IGNITION COIL-ON-PLUG Exploded View Removal and Installation 1. Disconnect the ignition coil electrical connector. 2. Remove the ignition coil retaining bolt. - To install, tighten to 10 Nm (89 lb-in). 3. Use a twisting motion while pulling up on the ignition coil and remove. 4. NOTE: Verify that the ignition coil spring is correctly located inside the ignition coil boot and that there is no damage to the tip of the boot. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3565 - Apply dielectric compound to the inside of the coil boots prior to installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 3570 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 3571 Knock Sensor: Locations Knock Sensor View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 3572 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 C109 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 3575 C108 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 3576 Knock Sensor: Diagrams Knock Sensor C1512 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 3577 C1514 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 3578 Knock Sensor: Description and Operation Knock Sensor (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 3579 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3585 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3586 Camshaft Position Sensor: Locations Camshaft Position Sensor View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3587 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor Camshaft Position Sensor: Diagrams Camshaft Position Sensor C180 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3590 C1180 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3591 C1366 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3592 C1367 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3593 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil on plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3594 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the camshaft position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. - Lubricate the CMP sensor O-ring seal with clean engine oil prior to installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3598 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3599 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3600 C101 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3601 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3602 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Rotate the accessory drive belt clockwise and detach the accessory drive belt from the A/C compressor pulley. 3. Loosen the A/C compressor bolts enough to slide the A/C compressor down approximately 25 mm (1 in), to allow access to the crankshaft position (CKP) sensor. To install, tighten to 25 Nm (18 lb-ft). 4. Disconnect the CKP sensor electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3603 5. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 6. To install, reverse the removal procedure. - Lubricate the O-ring seal with clean engine oil prior to installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Part 1 Part 2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Page 3608 Removal and Installation NOTE: - When a new lock cylinder is installed, the tailgate lock cylinder, door lock cylinders and the ignition lock cylinder should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is to be used, the new key code is attached to a tag. - The individual door lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build a new lock cylinder to the current key code of the vehicle. 1. Remove the steering wheel. 2. Remove bolt and the lower steering column shroud. 3. NOTE: The steering column shift is shown, the floor console shift is similar. Position the ignition lock cylinder cover aside. 4. Disconnect the PATS transceiver electrical connector. 5. Remove the screw and the PATS transceiver. 6. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove the lock cylinder. 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 3613 View 151-9 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 3614 Knock Sensor: Locations Knock Sensor View 151-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 > Page 3615 View 151-7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 C109 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 3618 C108 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 3619 Knock Sensor: Diagrams Knock Sensor C1512 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 3620 C1514 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3621 Knock Sensor: Description and Operation Knock Sensor (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3622 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions TSB 08-7-6 04/14/08 SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008 Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part List. ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and 2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07. ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and extract broken spark plugs. SERVICE PROCEDURE The engine build date can be read on the left hand cam cover information sticker. To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before removal is attempted. CAUTION DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS COULD BE DAMAGED. Spark Plug Removal Procedure 1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and surrounding valve cover area with compressed air. 2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4 teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark plug back and forth at this point. NOTE COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL. CAUTION EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE. CAUTION DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST ONLY BE REMOVED WITH HAND TOOLS. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3627 3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the back and forth turning as needed until turning effort is reduced, and remove the spark plugs. NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. (Figure 1) Separated/Broken Spark Plug Removal If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of three modes. Refer to the appropriate removal procedure as required. a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2) b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head. (Figure 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3628 c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground shield. (Figure 4) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3629 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3630 Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the cylinder head. (Figure 6) NOTE THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD. IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL. 1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be removed. (Figure 7) 2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and protect the combustion chamber from contamination. (Figure 7) 3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4 reduced diameter threads on the tip end). a. Coat the end of the tap with general purpose grease. (Figure 8) b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K) is provided with service tool 303-1203 update to connect the tap to a 3/8" socket Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3631 drive. CAUTION DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED. 4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9) a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out. b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to prevent thread stripping. c. Install the nylon washer and jack nut until finger tight. d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool assembly. NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. Mode 2 Procedure: 1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug well and allow 15 minutes of soak time. 2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking care not to fracture the porcelain. 3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder head. Mode 3 Procedure: CAUTION DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3632 Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground electrode shield. (FIGURE 10) Porcelain Removal - Preparation CAUTION THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21 °C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF ADHESIVE. CAUTION DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR BONDING. 1. Remove any remaining electrode material from broken porcelain with long nose reach pliers. 2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the straw nozzle supplied with the brake cleaner can. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3633 3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3634 4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14) NOTE PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN. 5. Insert the completed assembly into the spark plug well and fully engage the pin into the porcelain. (Figure 15) 6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to flood the porcelain and pin. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3635 7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take care making sure the pin does not disengage the porcelain. (Figure 16). 8. Repeat Steps 6 and 7. 9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry compressed air. NOTE CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN. 10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed. 11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry compressed air. Porcelain Removal - Bonding Process CAUTION USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER HEAD. NOTE WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES. 1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator. (Figure 17) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3636 2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18). 3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2. 4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent starts to cure. 5. Reassemble a dry and clean collet and pin assembly. 6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of Loctite® 638TMare being used if it drips off the pin. 7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin. 8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain with a twisting motion to spread the bonding agent. 9. Add additional Loctite® 638TM, repeating Steps 6-8. 10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19). CAUTION A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE EXTRACTION IS ATTEMPTED. 11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C). 12. Repeat the bonding process for remaining cylinders as needed. Porcelain Removal - Extraction 1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded rod. 2. Install the washer and jack nut until finger tight against the tool pilot bushing. CAUTION ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL. 3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is free of the ground electrode. 4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder head. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3637 NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7) Porcelain Removal - Pin Slipped Out In the unlikely event that the pin does not remove the broken porcelain, this process can be repeated. Key elements to success are: ^ Clean and dry porcelain ^ Sufficient Loctite® 638TM Retaining Compound spread uniformly ^ Loctite(R) 638(TM) cure time and temperature ^ Preventing the threaded rod from rotating while removing the porcelain Replacement Supplies Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT080706 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 12405 01 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > General Specifications Spark Plug: Specifications General Specifications Item....................................................................................................................................................... ..............................................................Specification Spark plug gap..................................................................................................................................... ....................................1.32-1.42 mm (0.052-0.056 in) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > General Specifications > Page 3640 Torque Specifications Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3641 Spark Plug: Application and ID Item....................................................................................................................................................... ..............................................................Specification Spark plug............................................................................................................................................ ...................................................................AGSF-32N Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3642 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Install a new spark plug. 2. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. ^ Install new spark plugs. 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3643 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a Heli-Coil(R) insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by white or light gray spots and with a bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Install new spark plugs. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3644 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3645 Spark Plug: Service and Repair SPARK PLUGS Exploded View Removal and Installation 1. Remove the ignition coil-on-plug. 2. CAUTION: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. - If an original spark plug is used, make sure it is installed in the same cylinder from which it was taken. New spark plugs can be used in any cylinder. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3646 Remove the spark plugs. To install, tighten to 15 Nm (11 lb-ft). 3. Inspect the spark plugs. Install new spark plugs as necessary. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3654 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3655 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3656 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3657 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3658 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3659 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3660 Pressure Regulating Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3661 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3662 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3663 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3664 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3665 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3666 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 3667 Pressure Regulating Solenoid: Service and Repair Electronic Pressure Control (EPC) Solenoid Removal CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. Disconnect the molded lead frame from the solenoids. 1 Disconnect the shift solenoid SSA and SSB. 2 Disconnect the torque converter clutch (TCC). 3 Disconnect the electronic pressure control (EPC) solenoid. 4 Disconnect the bulkhead interconnector. 4. Remove the EPC solenoid. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 3668 Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 lb-in). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame. 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 3669 4. Install the transmission fluid pan and filter. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams C2008 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Floor Shift Brake Shift Interlock Actuator - Floor Shift Brake Shift Interlock Actuator (BSIA) - Floor Shift Removal 1. Remove the floor console left side kick panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 3675 2. Lift the console storage lid cover and remove the console finish panel. 3. Disconnect the selector lever cable from the arm of the selector lever. 4. Disconnect the selector lever cable from the selector lever cable bracket on the selector lever. 5. Remove the selector lever bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 3676 6. Disconnect the selector lever electrical connector and remove the selector lever from the vehicle. 7. Disconnect the electrical connector. 1 Disconnect the overdrive cancel button electrical connector. 2 Cut the tie strap holding the wire harness to the base of the selector lever. 8. Remove the brake shift interlock actuator (BSIA). 1 Remove the bulb from the housing. 2 Cut the tie strap from the wire harness. 3 Remove the 2 screws and remove the BSIA. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 3677 Installation 1. Install the BSIA. 1 Install the BSIA and install the 2 screws. 2 Install the bulb into the housing. 3 Install a new tie strap on the wire harness. 2. Connect the electrical connector. 1 Connect the overdrive cancel button electrical connector. 2 Install a new tie strap to the wire harness. 3. Position the selector lever assembly in the console and install the bolts. ^ Tighten to 12 Nm (9 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 3678 4. Connect the selector lever electrical connector. 5. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable in the selector lever cable bracket. 6. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the selector lever arm. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 3679 7. Install the console finish panel. 8. Install the left console kick panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 3680 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the steering wheel. 3. Remove the 2 screws and the lower dash panel. 4. Remove the screw and the lower steering column shroud. 5. Remove the 2 screws and the upper steering column shroud. 6. Disconnect the clockspring electrical connectors. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 3681 7. Remove the screw and slide the multi-function switch up and position it aside. 8. Place a piece of tape on the clockspring to prevent it from rotating. 9. Press the 3 tabs on the clockspring and slide the clockspring off. 10. Remove the 3 screws and remove the clockspring and shroud mounting bracket. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 3682 11. Disconnect the brake shift interlock switch electrical connector. 12. Release the tab and slide the brake shift interlock down to remove. 13. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3687 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3688 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3689 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3690 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3691 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3692 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3693 Shift Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3694 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3695 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3696 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3697 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3698 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3699 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3700 Shift Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the shift solenoid operation information when carrying out Pinpoint Test A. See: Testing and Inspection/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3701 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always Off" Failed off due to PCM and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3702 Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Pinpoint Tests Refer to Vehicle/Diagrams for schematic and connector information. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3707 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3708 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3709 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3710 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3711 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3712 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3713 Torque Converter Clutch Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3714 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3715 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3716 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3717 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3718 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3719 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments Selector Lever Cable Adjustment Vehicles equipped with a floor mounted selector lever 1. Place the selector lever in the 1st position toward the rear of the vehicle. 2. Move the selector lever forward 2 detents. This should be the (D) position. Vehicles equipped with a column mounted selector lever 3. Rotate the selector lever clockwise until it bottoms out (1st gear), then rotate the selector lever counterclockwise 2 detent positions ((D) position). 4. Hang a 1.4 kg (3 lb) weight on the selector lever. All vehicles 5. With the vehicle in NEUTRAL, position it on a hoist. Vehicles equipped with a floor mounted selector lever 6. Rotate the cable adjustment lock upward and disconnect the selector lever cable from the manual control lever. Vehicles equipped with a column mounted selector lever 7. Slide the selector lever cable adjustment lock upwards and remove the cable from the manual control lever. 8. Rotate the manual control lever forward until the travel stops. Then rotate the manual control lever back 2 detents to the (D) position. Vehicles equipped with a floor mounted selector lever Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments > Page 3725 9. NOTE: Check to be sure that the selector lever cable retainer is correctly installed in the selector lever cable bracket. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the manual control lever and rotate the lock downward to lock the adjuster. Vehicles equipped with a column mounted selector lever 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the manual control lever and slide the lock downward to lock the adjuster. 11. Verify that the engine will start in PARK and NEUTRAL. Verify that the reverse lamps will illuminate in the REVERSE position. If not, check the adjustment of the transmission range (TR) sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay Transfer Case Actuator Relay: Testing and Inspection Counter Clockwise (CCW) Motor 4X4 Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay > Page 3735 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay > Page 3736 Transfer Case Actuator Relay: Testing and Inspection Clockwise (CW) Motor 4X4 Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay > Page 3737 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 3744 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 3745 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 3746 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 3747 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 3748 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 3749 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 3750 Brake Switch - TCC: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 3751 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 3752 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 3753 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 3754 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 3755 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 3756 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 3757 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations View 151-19 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3763 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3764 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3765 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3766 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3767 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3768 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3769 Overdrive Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3770 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3771 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3772 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3773 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3774 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3775 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3776 C2135 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions Throttle Position Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3781 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3782 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3783 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3784 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3785 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3786 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3787 Throttle Position Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3788 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3789 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3790 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3791 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3792 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3793 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions Transmission Mode Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3798 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3799 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3800 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3801 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3802 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3803 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3804 Transmission Mode Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3805 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3806 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3807 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3808 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3809 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3810 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Page 3811 Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Service and Repair > Transmission Control (TC) Switch - Column Shift Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift Transmission Control (TC) Switch - Column Shift Removal and Installation NOTE: The transmission control (TC) switch is part of the transmission range selector lever. 1. To install a new TC switch, a new transmission range selector lever must be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 3814 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Removal 1. Lift the center console lid cover and remove the console finish panel. 2. Depress the bottom of the button. Using a suitable tool, pry forward on the top of the selector lever button and remove the selector lever button. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 3815 3. Remove the screw, slide the selector lever knob up and remove the selector lever knob. 4. Remove the selector lever knob shroud. 5. Disconnect the transmission control (TC) switch electrical connector, release the selector lever bezel locking tabs and remove the selector lever bezel from the selector lever. 6. Release the 2 tabs and push the TC switch through the selector lever bezel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 3816 Installation 1. Install the TC switch in the selector lever bezel. 2. Install the selector lever bezel on the locking tabs and connect the TC switch electrical connector. 3. Install the selector lever knob shroud. 4. CAUTION: Do not overtighten the screw or damage to the selector lever knob can occur. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 3817 Install the selector lever knob and install the screw. 5. Position the selector lever button in place and press in on the top of the selector lever button to install. 6. Install the center console finish panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 Transmission Position Switch/Sensor: Locations View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 3821 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3824 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3825 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3826 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3827 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3828 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3829 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3830 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3831 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3832 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3833 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3834 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3835 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3836 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 3837 C167 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 3838 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the selector lever cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 4. Loosen the digital transmission range (TR) sensor bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 3839 5. NOTE: The manual control lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 lb-in). 7. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever shaft outer nut. ^ Tighten to 33 Nm (24 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 3840 8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. With the manual control lever in overdrive connect the selector lever cable. 9. Lower the vehicle. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 3841 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Removal NOTE: The manual control lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the selector lever cable. Disconnect the selector lever cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 3842 3. Disconnect the digital transmission range (TR) electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 3843 Installation 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 3844 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 lb-ft). 5. Connect the digital TR sensor electrical connector. 6. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable end to the manual control lever with the lever in the (D) position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 3845 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Locations Output Shaft Speed (OSS) Sensor View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 3850 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 3851 View 151-12 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 3852 Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 3853 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3856 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3857 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3858 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3859 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3860 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3861 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3862 Transmission Speed Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3863 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3864 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3865 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3866 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3867 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3868 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3869 Transmission Speed Sensor: Connector Views C193 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3870 C1107 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3871 C143 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 3. Remove the TSS sensor bolt and sensor. ^ Remove the TSS sensor bolt. ^ Remove the TSS sensor. 4. To install, reverse the removal procedure. ^ Tighten bolt to 11 Nm (8 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3874 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the output shaft speed (OSS) sensor electrical connector. 3. Remove the OSS sensor bolt and sensor. ^ Remove the OSS sensor bolt. ^ Remove the OSS sensor. 4. To install, reverse the removal procedure. ^ Tighten bolt to 12 Nm (9 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3879 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3880 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3881 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3882 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3883 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3884 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3885 Transmission Temperature Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3886 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3887 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3888 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3889 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3890 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 3891 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 08-4-4 > Mar > 08 > Engine Controls - Cold Start Hesitation/Intake Backfire PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Cold Start Hesitation/Intake Backfire TSB 08-4-4 03/03/08 COLD START ROUGH RUNNING/HESITATION/BACKFIRE - 4.6 ONLY FORD: 2007-2008 F-150 ISSUE Some 2007-2008 F-150 vehicles equipped with a 4.6L engine, may exhibit a rough running, hesitation and/or induction backfire during the first drive away event following an overnight or extended soak. No diagnostic trouble codes (DTCs) or other driveability concerns should be observed. This typically occurs when the ambient temperature is below 60 °F (16 °C). The event will last only 20-40 seconds and normal operation will return once the system enters closed loop. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF OTHER DRIVEABILITY CONCERNS ARE PRESENT OR NOTED BY THE CUSTOMER, DO NOT CONTINUE WITH THIS TSB. FOLLOW NORMAL WORKSHOP MANUAL (WSM) DIAGNOSTICS. NOTE NO DTC'S WILL BE PRESENT WITH THE CONDITION THIS CALIBRATION IS DESIGNED TO ADDRESS. IF DTC'S ARE PRESENT DO NOT CONTINUE WITH THIS TSB. FOLLOW NORMAL WSM DIAGNOSTICS. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 53.4 and higher. This new calibration is not included in the VCM 2008.1 DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 080404A 2007-2008 F-150 4.6: 0.3 Hr. Check DTCs Reprogram The PCM Authorization Decal Not Required (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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: > 08-4-4 > Mar > 08 > Engine Controls - Cold Start Hesitation/Intake Backfire PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Cold Start Hesitation/Intake Backfire TSB 08-4-4 03/03/08 COLD START ROUGH RUNNING/HESITATION/BACKFIRE - 4.6 ONLY FORD: 2007-2008 F-150 ISSUE Some 2007-2008 F-150 vehicles equipped with a 4.6L engine, may exhibit a rough running, hesitation and/or induction backfire during the first drive away event following an overnight or extended soak. No diagnostic trouble codes (DTCs) or other driveability concerns should be observed. This typically occurs when the ambient temperature is below 60 °F (16 °C). The event will last only 20-40 seconds and normal operation will return once the system enters closed loop. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF OTHER DRIVEABILITY CONCERNS ARE PRESENT OR NOTED BY THE CUSTOMER, DO NOT CONTINUE WITH THIS TSB. FOLLOW NORMAL WORKSHOP MANUAL (WSM) DIAGNOSTICS. NOTE NO DTC'S WILL BE PRESENT WITH THE CONDITION THIS CALIBRATION IS DESIGNED TO ADDRESS. IF DTC'S ARE PRESENT DO NOT CONTINUE WITH THIS TSB. FOLLOW NORMAL WSM DIAGNOSTICS. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 53.4 and higher. This new calibration is not included in the VCM 2008.1 DVD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 080404A 2007-2008 F-150 4.6: 0.3 Hr. Check DTCs Reprogram The PCM Authorization Decal Not Required (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3912 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3913 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3914 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3915 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3916 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3917 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3918 Pressure Regulating Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3919 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3920 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3921 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3922 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3923 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3924 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 3925 Pressure Regulating Solenoid: Service and Repair Electronic Pressure Control (EPC) Solenoid Removal CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. Disconnect the molded lead frame from the solenoids. 1 Disconnect the shift solenoid SSA and SSB. 2 Disconnect the torque converter clutch (TCC). 3 Disconnect the electronic pressure control (EPC) solenoid. 4 Disconnect the bulkhead interconnector. 4. Remove the EPC solenoid. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 3926 Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 lb-in). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame. 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 3927 4. Install the transmission fluid pan and filter. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams C2008 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Floor Shift Brake Shift Interlock Actuator - Floor Shift Brake Shift Interlock Actuator (BSIA) - Floor Shift Removal 1. Remove the floor console left side kick panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 3933 2. Lift the console storage lid cover and remove the console finish panel. 3. Disconnect the selector lever cable from the arm of the selector lever. 4. Disconnect the selector lever cable from the selector lever cable bracket on the selector lever. 5. Remove the selector lever bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 3934 6. Disconnect the selector lever electrical connector and remove the selector lever from the vehicle. 7. Disconnect the electrical connector. 1 Disconnect the overdrive cancel button electrical connector. 2 Cut the tie strap holding the wire harness to the base of the selector lever. 8. Remove the brake shift interlock actuator (BSIA). 1 Remove the bulb from the housing. 2 Cut the tie strap from the wire harness. 3 Remove the 2 screws and remove the BSIA. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 3935 Installation 1. Install the BSIA. 1 Install the BSIA and install the 2 screws. 2 Install the bulb into the housing. 3 Install a new tie strap on the wire harness. 2. Connect the electrical connector. 1 Connect the overdrive cancel button electrical connector. 2 Install a new tie strap to the wire harness. 3. Position the selector lever assembly in the console and install the bolts. ^ Tighten to 12 Nm (9 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 3936 4. Connect the selector lever electrical connector. 5. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable in the selector lever cable bracket. 6. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the selector lever arm. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 3937 7. Install the console finish panel. 8. Install the left console kick panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 3938 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the steering wheel. 3. Remove the 2 screws and the lower dash panel. 4. Remove the screw and the lower steering column shroud. 5. Remove the 2 screws and the upper steering column shroud. 6. Disconnect the clockspring electrical connectors. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 3939 7. Remove the screw and slide the multi-function switch up and position it aside. 8. Place a piece of tape on the clockspring to prevent it from rotating. 9. Press the 3 tabs on the clockspring and slide the clockspring off. 10. Remove the 3 screws and remove the clockspring and shroud mounting bracket. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 3940 11. Disconnect the brake shift interlock switch electrical connector. 12. Release the tab and slide the brake shift interlock down to remove. 13. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3945 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3946 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3947 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3948 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3949 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3950 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3951 Shift Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3952 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3953 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3954 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3955 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3956 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3957 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3958 Shift Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the shift solenoid operation information when carrying out Pinpoint Test A. See: Transmission Control Systems/Testing and Inspection/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3959 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always Off" Failed off due to PCM and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 3960 Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Pinpoint Tests Refer to Vehicle/Diagrams for schematic and connector information. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3965 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3966 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3967 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3968 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3969 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3970 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3971 Torque Converter Clutch Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3972 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3973 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3974 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3975 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3976 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3977 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3984 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3985 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3986 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3987 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3988 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3989 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3990 Pressure Regulating Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3991 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3992 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3993 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3994 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3995 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3996 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 3997 Pressure Regulating Solenoid: Service and Repair Electronic Pressure Control (EPC) Solenoid Removal CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. Disconnect the molded lead frame from the solenoids. 1 Disconnect the shift solenoid SSA and SSB. 2 Disconnect the torque converter clutch (TCC). 3 Disconnect the electronic pressure control (EPC) solenoid. 4 Disconnect the bulkhead interconnector. 4. Remove the EPC solenoid. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 3998 Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 lb-in). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame. 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 3999 4. Install the transmission fluid pan and filter. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Diagrams C2008 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Floor Shift Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Floor Shift Brake Shift Interlock Actuator - Floor Shift Brake Shift Interlock Actuator (BSIA) - Floor Shift Removal 1. Remove the floor console left side kick panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Floor Shift > Page 4005 2. Lift the console storage lid cover and remove the console finish panel. 3. Disconnect the selector lever cable from the arm of the selector lever. 4. Disconnect the selector lever cable from the selector lever cable bracket on the selector lever. 5. Remove the selector lever bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Floor Shift > Page 4006 6. Disconnect the selector lever electrical connector and remove the selector lever from the vehicle. 7. Disconnect the electrical connector. 1 Disconnect the overdrive cancel button electrical connector. 2 Cut the tie strap holding the wire harness to the base of the selector lever. 8. Remove the brake shift interlock actuator (BSIA). 1 Remove the bulb from the housing. 2 Cut the tie strap from the wire harness. 3 Remove the 2 screws and remove the BSIA. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Floor Shift > Page 4007 Installation 1. Install the BSIA. 1 Install the BSIA and install the 2 screws. 2 Install the bulb into the housing. 3 Install a new tie strap on the wire harness. 2. Connect the electrical connector. 1 Connect the overdrive cancel button electrical connector. 2 Install a new tie strap to the wire harness. 3. Position the selector lever assembly in the console and install the bolts. ^ Tighten to 12 Nm (9 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Floor Shift > Page 4008 4. Connect the selector lever electrical connector. 5. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable in the selector lever cable bracket. 6. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the selector lever arm. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Floor Shift > Page 4009 7. Install the console finish panel. 8. Install the left console kick panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Floor Shift > Page 4010 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the steering wheel. 3. Remove the 2 screws and the lower dash panel. 4. Remove the screw and the lower steering column shroud. 5. Remove the 2 screws and the upper steering column shroud. 6. Disconnect the clockspring electrical connectors. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Floor Shift > Page 4011 7. Remove the screw and slide the multi-function switch up and position it aside. 8. Place a piece of tape on the clockspring to prevent it from rotating. 9. Press the 3 tabs on the clockspring and slide the clockspring off. 10. Remove the 3 screws and remove the clockspring and shroud mounting bracket. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Floor Shift > Page 4012 11. Disconnect the brake shift interlock switch electrical connector. 12. Release the tab and slide the brake shift interlock down to remove. 13. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4017 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4018 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4019 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4020 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4021 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4022 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4023 Shift Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4024 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4025 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4026 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4027 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4028 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4029 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4030 Shift Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the shift solenoid operation information when carrying out Pinpoint Test A. See: Transmission Control Systems/Testing and Inspection/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4031 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always Off" Failed off due to PCM and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4032 Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Pinpoint Tests Refer to Vehicle/Diagrams for schematic and connector information. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4037 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4038 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4039 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4040 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4041 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4042 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4043 Torque Converter Clutch Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4044 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4045 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4046 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4047 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4048 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4049 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 1-2 Accumulator Accumulator: Service and Repair 1-2 Accumulator 1-2 Accumulator Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. Compress the 1-2 accumulator piston and remove the accumulator piston retaining ring. 4. Remove the 1-2 shift accumulator assembly. 1 Remove the 1-2 accumulator cover. 2 Remove the inner and outer 1-2 accumulator springs. 3 Remove the 1-2 accumulator piston. 4 Remove the 1-2 accumulator upper spring. Installation 1. Install the 1-2 shift accumulator assembly. 1 Install the 1-2 accumulator upper spring. 2 Install the 1-2 accumulator piston. 3 Install the inner and outer 1-2 accumulator springs. 4 Install the 1-2 accumulator cover. 2. Compress the 1-2 accumulator piston and remove the accumulator piston retaining ring. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 1-2 Accumulator > Page 4054 3. Install the transmission fluid pan and filter. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 1-2 Accumulator > Page 4055 Accumulator: Service and Repair 2-3 Accumulator 2-3 Accumulator Removal 1. Remove the main control valve body. 2. Remove the 2-3 accumulator piston retainer. 3. Remove the accumulator piston and spring. Installation 1. Install the 2-3 accumulator assembly. 1 Install the accumulator piston. 2 Install the accumulator piston spring. 3 Install the accumulator spring retainer. 2. Install the main control valve body. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Band and Clutch Application Chart A Band: Specifications Band and Clutch Application Chart A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Band and Clutch Application Chart A > Page 4060 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4065 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4066 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4067 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4068 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4069 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4070 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4071 Brake Switch - TCC: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4072 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4073 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4074 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4075 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4076 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4077 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Page 4078 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Forward Clutch Pack Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Forward Clutch Pack > Page 4083 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Forward Clutch Pack > Page 4084 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Forward Clutch Pack > Page 4085 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid .............................................................................................................................. .................................................... 13.9 quarts (13.2L) NOTE: Approximate dry fill capacity including transmission fluid cooling system, actual refill capacities will vary based on vehicle application and transmission fluid cooling system (i.e. coolers size, cooling lines, auxiliary cooler capacities). The amount of transmission fluid and fluid level should be set by the indication on the dipsticks normal operating range. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4090 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ............................................ MERCON V XT-5-QM Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill Fluid - A/T: Service and Repair Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill Draining, all vehicles using a suitable flush and fill machine CAUTION: Always refer to the instructions supplied with the flush and fill machine, or transmission damage may occur. NOTE: Draining fluid from the transmission by removing only the transmission fluid pan is acceptable for normal or severe duty transmission fluid maintenance. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Use a suitable flush and fill machine to change the transmission fluid. 3. When connecting the flush and fill machine, connect the machine to the transmission fluid cooler tube after the transmission fluid cooler on the transmission fluid cooler return tube. This will help remove any foreign material trapped in the transmission fluid coolers. Refill 1. Use only clean transmission fluid. 2. Once the transmission fluid exchange has been completed, disconnect the flush and fill machine. Reconnect any disconnected transmission fluid cooler tubes. 3. With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved (transmission fluid should be in the cross-hatched area of the transmission fluid level indicator). Draining, all vehicles not using a suitable flush and fill machine 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Loosen the transmission fluid pan bolts and allow the transmission fluid to drain. 3. After the transmission fluid has drained, remove the transmission fluid pan. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4093 4. Do not remove the transmission fluid filter. It is not necessary to change the transmission fluid filter during a normal maintenance transmission fluid change. 5. Clean and inspect the transmission fluid pan, transmission fluid pan gasket and magnet. 6. Thoroughly flush the transmission fluid cooler tubes. Refill 1. Position the magnet into the transmission fluid pan. 2. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and transmission fluid pan gasket. 1 Position the transmission fluid pan with the transmission fluid pan gasket in place. 2 Install the bolts. ^ Tighten to 14 Nm (10 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4094 3. CAUTION: The use of any other transmission fluid can result in the transmission failing to operate in a normal manner or transmission failure. Fill the transmission. ^ Add 4.7L (5 qt) of clean transmission fluid to the transmission through the transmission fluid filler tube. 4. Start the engine. Move the selector lever through all the gear ranges, checking for engagements. 5. With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved (transmission fluid should be in the cross-hatched area of the transmission fluid level indicator). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4095 Fluid - A/T: Service and Repair Transmission Fluid Cooler Backflushing and Cleaning Transmission Fluid Cooler Backflushing and Cleaning 1. CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail; this will effect the operation of the transmission. Conduct backflushing with a suitable torque converter/fluid cooler cleaner. Test your equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new filter in the flush equipment if flow is weak or contaminated. 2. If equipped, remove and discard the transmission fluid in-line filter. 3. Remove the transmission fluid cooler bypass valve and install rubber hoses in its place. 4. To aid in attaching the cleaner to the transmission steel cooler tubes, connect 2 additional rubber hoses to the transmission end of the steel transmission cooler tubes. ^ Connect the cleaner tank pressure tubes to the steel transmission cooler return tubes (longest tube). ^ Connect a tank return hose to the steel transmission cooler pressure tubes (shorter tube). Place the outlet end of this hose in the tank reservoir. 5. Turn on the pump and allow the transmission fluid to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in cooler system). 6. Switch off the pump and disconnect the pressure hose from the transmission cooler return tube. 7. Use compressed air to blow out the cooler(s) and tubes (blow air into the transmission cooler return tubes) until all fluid is removed. 8. Remove the rubber return hose from the remaining steel cooler tube. 9. Remove the rubber hoses and reinstall the transmission fluid cooler bypass valve. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter Fluid Filter - A/T: Service and Repair Fluid Pan, Gasket and Filter Fluid Pan, Gasket and Filter Removal CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail; this will effect the operation of the transmission. Use of a transmission fluid other than specified could result in transmission failure. NOTE: Normal maintenance requires periodic automatic transmission fluid changes. If a major repair, such as a clutch, band or bearing, is required, the automatic transmission will need to be removed for repair. The transmission fluid needs to be changed if evidence of transmission fluid contamination is found. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid. ^ Loosen the transmission fluid pan bolts and allow transmission fluid to drain. After transmission fluid is drained remove the bolts. 3. Remove the transmission fluid pan and transmission fluid pan gasket. 4. Pull down evenly and remove the transmission fluid filter and seal. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 4100 5. Clean and inspect the transmission fluid pan, gasket and magnet. Installation 1. CAUTION: If installing a new transmission fluid filter and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. NOTE: If transmission is being repaired for a contamination-related failure, use a new transmission fluid filter and seal. The transmission fluid filter may be reused if no excessive contamination is present. Install a new transmission fluid filter and seal as required. 2. Position the pan magnet into the transmission fluid pan. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 4101 3. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage; if not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and gasket. 1 Position the transmission fluid pan and gasket. 2 Install the transmission fluid pan bolts. ^ Tighten to 14 Nm (10 lb-ft). 4. NOTE: When filling a dry transmission and converter, start with a minimum of 4.7L (5 qt). Fill the transmission to the correct level with clean transmission fluid. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 4102 Fluid Filter - A/T: Service and Repair Transmission Filter - In Line Transmission Filter - In Line Transmission fluid in-line filter - with an oil-to-air (OTA) cooler NOTE: Use the following guidelines for installing the transmission fluid in-line filter: ^ If the transmission was overhauled and the vehicle was equipped with a transmission fluid in-line filter, install a new transmission fluid in-line filter. ^ If the transmission was overhauled and the vehicle was not equipped with a transmission fluid in-line filter, install a new transmission fluid in-line filter kit. ^ If the transmission is being installed for a non-internal repair, do not install a transmission fluid in-line filter or filter kit. ^ If installing a new or a Ford-authorized remanufactured transmission, install a transmission fluid in-line filter. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the bolts and the skid plate. 3. Remove the section of the rubber hose and steel tube as illustrated. ^ Clean and de-burr the end of the steel tube. 4. NOTE: Be sure the transmission fluid cooler tube is fully seated in the body of the fitting before final tightening of the ferrule nut. Install the tubing ferrule hose assembly connector onto the end of the steel transmission fluid cooler tube. Finger-tighten the ferrule nut, then tighten the nut an additional 1-1/2 turns to seat the ferrule in the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 4103 5. CAUTION: The transmission fluid in-line filter has a bypass valve in it. The arrow on the transmission fluid in-line filter indicates the direction of transmission fluid flow through the transmission fluid in-line filter. The transmission fluid in-line filter must be installed in the transmission fluid cooler return tube with the arrow on the transmission fluid in-line filter pointing away from the transmission fluid cooler and toward the transmission (the return tube has transmission fluid coming out of the cooler going to the transmission). If the transmission fluid in-line filter is not installed correctly, it will cause internal transmission damage. CAUTION: Do not install any rubber hoses or steel tubing with a bend entering the filter greater than 60 degrees. Using a suitable length of hose install the transmission fluid in-line filter. Tighten the hose clamps. 6. Clean a section of the transmission fluid pan and install the sticker. 7. If equipped, install the skid plate and the bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 4104 8. Fill the transmission with clean transmission fluid. ^ Verify for correct operation. ^ Check the filter for leaks. Transmission fluid in-line filter - without an OTA cooler NOTE: Use the following guidelines for installing the transmission fluid in-line filter: ^ If the transmission was overhauled and the vehicle was equipped with a transmission fluid in-line filter, install a new transmission fluid in-line filter. ^ If the transmission was overhauled and the vehicle was not equipped with a transmission fluid in-line filter, install a new transmission fluid in-line filter kit. ^ If the transmission is being installed for a non-internal repair, do not install a transmission fluid in-line or filter kit. ^ If installing a new or a Ford-authorized remanufactured transmission, install a transmission fluid in-line filter. 9. With the vehicle in NEUTRAL, position it on a hoist. 10. Remove the cooler tubes retainers. 11. Remove the section of the steel tube as illustrated. ^ Clean and de-burr the end of the steel tubes. 12. NOTE: Be sure the cooler tube is fully seated in the body of the fitting before final tightening of the ferrule nut. Install the tubing ferrule hose assembly connector onto the end of the steel fluid cooler tubes. Finger-tighten the ferrule nut, then tighten the nut an Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 4105 additional 1-1/2 turns to seat the ferrule in the connector. 13. CAUTION: The transmission fluid in-line filter has a bypass valve in it. The arrow on the transmission fluid in-line filter indicates the direction of transmission fluid flow through the transmission fluid in-line filter. The transmission fluid in-line filter must be installed in the transmission fluid cooler return tube with the arrow on the transmission fluid in-line filter pointing away from the transmission fluid cooler and toward the transmission (the return tube has transmission fluid coming out of the cooler going to the transmission). If the transmission fluid in-line filter is not installed correctly, it will cause internal transmission damage. CAUTION: Do not install any rubber hoses or steel tubing with a bend entering the filter greater than 60 degrees. Using a suitable length of hose install the transmission fluid in-line filter. Tighten the hose clamps. 14. Install one cooler tube retainer as illustrated. 15. Secure the cooler tubes together with a tie strap. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 4106 16. Clean a section of the transmission fluid pan and install the sticker. 17. Fill the transmission with clean transmission fluid. ^ Verify for correct operation. ^ Check the filter for leaks. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Tubes Without Auxiliary Transmission Fluid Cooler (Part 1) Without Auxiliary Transmission Fluid Cooler (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Page 4110 With Auxiliary Transmission Fluid Cooler (Part 1) With Auxiliary Transmission Fluid Cooler (Part 2) Removal 1. If not done previously, carry out the transmission fluid cooler flow test procedure. 2. With the vehicle in NEUTRAL, position it on a hoist. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Page 4111 3. Remove the bolts and the skid plate (four wheel drive [4WD] vehicles). 4. Remove the fasteners and position the air deflector aside. 5. Disconnect the transmission fluid cooler tubes from the transmission case. 6. Remove the secondary latches from the transmission fluid cooler tubes. 7. Remove the transmission fluid cooler tubes from the bracket. 8. Remove the transmission fluid cooler tubes from the retainer. 9. Using the special tool, disconnect the transmission fluid cooler tubes from the radiator, and if equipped, the transmission fluid cooler. Installation 1. Install the transmission fluid cooler tube(s). ^ Tighten to 27 Nm (20 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Page 4112 2. Connect the transmission fluid cooler tubes to the bracket. 3. Install the transmission fluid cooler tubes to the retainer. 4. Connect the transmission fluid cooler tubes to the radiator and the auxiliary transmission fluid cooler if equipped. 5. Install the secondary latches onto the transmission fluid cooler tubes. 6. Position the air deflector and install the fasteners. 7. Position the skid plate and install the bolts (4WD vehicles). ^ Tighten to 15 Nm (11 lb-ft). 8. Fill the transmission with clean transmission fluid specified for this transmission. 9. Check for leaks. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Transmission fluid pan and gasket ...................................................................................................... ......................................................... 14 Nm (10 lb-ft) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4116 Fluid Pan: Service and Repair Fluid Pan, Gasket and Filter Removal CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail; this will effect the operation of the transmission. Use of a transmission fluid other than specified could result in transmission failure. NOTE: Normal maintenance requires periodic automatic transmission fluid changes. If a major repair, such as a clutch, band or bearing, is required, the automatic transmission will need to be removed for repair. The transmission fluid needs to be changed if evidence of transmission fluid contamination is found. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid. ^ Loosen the transmission fluid pan bolts and allow transmission fluid to drain. After transmission fluid is drained remove the bolts. 3. Remove the transmission fluid pan and transmission fluid pan gasket. 4. Pull down evenly and remove the transmission fluid filter and seal. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4117 5. Clean and inspect the transmission fluid pan, gasket and magnet. Installation 1. CAUTION: If installing a new transmission fluid filter and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. NOTE: If transmission is being repaired for a contamination-related failure, use a new transmission fluid filter and seal. The transmission fluid filter may be reused if no excessive contamination is present. Install a new transmission fluid filter and seal as required. 2. Position the pan magnet into the transmission fluid pan. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4118 3. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage; if not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and gasket. 1 Position the transmission fluid pan and gasket. 2 Install the transmission fluid pan bolts. ^ Tighten to 14 Nm (10 lb-ft). 4. NOTE: When filling a dry transmission and converter, start with a minimum of 4.7L (5 qt). Fill the transmission to the correct level with clean transmission fluid. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments Selector Lever Cable Adjustment Vehicles equipped with a floor mounted selector lever 1. Place the selector lever in the 1st position toward the rear of the vehicle. 2. Move the selector lever forward 2 detents. This should be the (D) position. Vehicles equipped with a column mounted selector lever 3. Rotate the selector lever clockwise until it bottoms out (1st gear), then rotate the selector lever counterclockwise 2 detent positions ((D) position). 4. Hang a 1.4 kg (3 lb) weight on the selector lever. All vehicles 5. With the vehicle in NEUTRAL, position it on a hoist. Vehicles equipped with a floor mounted selector lever 6. Rotate the cable adjustment lock upward and disconnect the selector lever cable from the manual control lever. Vehicles equipped with a column mounted selector lever 7. Slide the selector lever cable adjustment lock upwards and remove the cable from the manual control lever. 8. Rotate the manual control lever forward until the travel stops. Then rotate the manual control lever back 2 detents to the (D) position. Vehicles equipped with a floor mounted selector lever Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments > Page 4123 9. NOTE: Check to be sure that the selector lever cable retainer is correctly installed in the selector lever cable bracket. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the manual control lever and rotate the lock downward to lock the adjuster. Vehicles equipped with a column mounted selector lever 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the manual control lever and slide the lock downward to lock the adjuster. 11. Verify that the engine will start in PARK and NEUTRAL. Verify that the reverse lamps will illuminate in the REVERSE position. If not, check the adjustment of the transmission range (TR) sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations View 151-19 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4132 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4133 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4134 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4135 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4136 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4137 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4138 Overdrive Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4139 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4140 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4141 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4142 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4143 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4144 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4145 C2135 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4150 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4151 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4152 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4153 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4154 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4155 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4156 Pressure Regulating Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4157 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4158 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4159 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4160 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4161 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4162 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4163 Pressure Regulating Solenoid: Service and Repair Electronic Pressure Control (EPC) Solenoid Removal CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. Disconnect the molded lead frame from the solenoids. 1 Disconnect the shift solenoid SSA and SSB. 2 Disconnect the torque converter clutch (TCC). 3 Disconnect the electronic pressure control (EPC) solenoid. 4 Disconnect the bulkhead interconnector. 4. Remove the EPC solenoid. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4164 Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 lb-in). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame. 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4165 4. Install the transmission fluid pan and filter. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket Seals and Gaskets: Service and Repair Extension Housing Gasket Extension Housing Gasket Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Rear wheel drive (RWD) vehicles 2. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they may be installed in their original positions. Mark the driveshaft flange and the rear pinion flange for correct alignment during assembly. 3. Remove the 4 rear driveshaft bolts. Four wheel drive (4WD) vehicles 4. Remove the transfer case. All vehicles 5. Using a suitable high-lift jack, support the transmission. 6. Remove the 2 bolts from the exhaust hanger. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4170 7. Remove the bolt for the LH heat shield to the transmission support crossmember. 8. Remove the bolt for the RH heat shield to the transmission support crossmember. 9. Loosen, but do not remove the transmission-to-crossmember nuts. 10. Remove the 4 crossmember-to-frame nuts and bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4171 11. Remove the transmission mount-to-crossmember nuts and remove the crossmember. 12. Remove the 2 bolts and the rear transmission mount. 13. Lower the transmission to access the extension housing bolts. 14. Remove the extension housing and gasket. 1 Remove the bolts and nuts. 2 Remove the extension housing and gasket. Installation Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4172 All vehicles 1. Install the extension housing and gasket. 1 Install the extension housing and gasket. 2 Install the bolts. ^ Tighten to 27 Nm (20 lb-ft). 2. Raise and position the transmission. 3. Position the rear transmission insulator and install the bolts. ^ Tighten to 80 Nm (59 lb-ft). 4. Position the crossmember and loosely install the transmission mount-to-crossmember nut. 5. Install the 4 crossmember-to-frame nuts and bolts. ^ Tighten to 115 Nm (85 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4173 6. Lower the transmission on the crossmember and tighten the rear mount nuts. ^ Tighten to 103 Nm (76 lb-ft). 7. Install the bolts retaining the exhaust hanger to the crossmember. ^ Tighten to 40 Nm (30 lb-ft). 8. Remove the high-lift transmission jack. 9. Install the bolt for the LH heat shield to the transmission support crossmember. ^ Tighten to 20 Nm (15 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4174 10. Install the bolt for the RH heat shield to the transmission support crossmember. ^ Tighten to 20 Nm (15 lb-ft). 4WD vehicles 11. Install the transfer case. RWD vehicles 12. NOTE: The output shaft and the driveshaft are a balanced assembly. Install the driveshaft. ^ Align the yellow dots and position the driveshaft on the transmission. 13. NOTE: To maintain driveshaft balance, install the driveshaft yoke and flange in the original position that was marked during removal. Install the 4 driveshaft bolts. ^ Tighten to 103 Nm (76 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4175 All vehicles 14. Lower the vehicle. 15. Fill the transmission with clean transmission fluid. ^ Verify for correct operation. ^ Check for leaks. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4176 Seals and Gaskets: Service and Repair Extension Housing Seal Extension Housing Seal Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The output shaft and driveshaft are a balanced assembly. Mark the driveshaft flange and the rear pinion flange for correct alignment during assembly. 3. Remove the 4 driveshaft bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4177 4. Slide the driveshaft back enough to index-mark the driveshaft, the extension housing and the output shaft. Separate the driveshaft from the transmission. 5. Using the special tools, remove the extension housing seal. Installation 1. NOTE: When installing the new seal, make sure that the drain hole in the seal is in the 6 o'clock position. Using the special tool, install a new extension housing seal. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4178 2. NOTE: The output shaft and the driveshaft are a balanced assembly. Install the driveshaft. ^ Align all the index marks and position the driveshaft on the transmission. ^ Install the driveshaft. 3. NOTE: To maintain driveshaft balance, install the driveshaft yoke and flange in the original position that was marked during removal. Install the rear driveshaft and the 4 bolts. ^ Tighten to 103 Nm (76 lb-ft). 4. Check the level of the transmission fluid, add clean transmission fluid as necessary. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4179 Seals and Gaskets: Service and Repair Manual Control Lever Shaft and Seal Manual Control Lever Shaft and Seal Removal CAUTION: Use care not to damage the manual control lever shaft bore. The new seal can leak. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. NOTE: When removing the manual control lever shaft retaining pin, use a soft cloth to protect the surface of the case. All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four wheel drive (4WD) vehicles 2. Remove the front driveshaft shield nuts and remove the shield. 3. NOTE: Index-mark the front and rear flange. NOTE: It is not necessary to remove the front driveshaft from the vehicle. Index-mark the front and rear flange, disconnect the front driveshaft and position aside. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4180 All vehicles 4. Loosen, but do not remove the transmission fluid pan bolts and allow the transmission fluid to drain. Once the transmission fluid has drained, remove the bolts. 5. Remove the transmission fluid pan and gasket. 6. Disconnect the selector lever cable end. 7. Disconnect the digital transmission range (TR) electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4181 8. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 9. Remove the digital TR sensor bolts and the sensor. 10. Remove the manual control valve detent lever bolt and spring. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4182 11. Remove the manual control lever shaft retaining pin. 12. Remove the inner manual control lever shaft nut and slide the manual control lever shaft out of the case. 13. Remove the parking lever actuating rod. 1 Remove the manual valve detent lever. 2 Remove the parking lever actuating rod. 14. Remove the manual control lever shaft seal. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4183 Installation All vehicles 1. Using the special tool, install the manual control lever seal. 2. Install the parking lever actuating rod. 1 Install the parking lever actuating rod. 2 Install the manual valve detent lever. 3. Install the manual control lever shaft. 1 Install the manual control lever shaft. 2 Install the inner manual control lever shaft nut. ^ Tighten to 31 Nm (23 lb-ft). 3 Install the manual valve control lever shaft retaining pin. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4184 4. Install the manual control valve detent lever spring and bolt. ^ Tighten to 10 Nm (89 lb-in). 5. Install the digital TR sensor and loosely install the bolts. 6. NOTE: The manual control lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4185 7. CAUTION: Tightening one screw before tightening the other may cause the digital transmission range (TR) sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 lb-in). 8. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 lb-ft). 9. Connect the digital TR sensor electrical connector. 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable end to the manual control lever with the lever in the (D) position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4186 11. Position the pan magnet into the transmission fluid pan. 12. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage; if not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and gasket. 1 Position the transmission fluid pan and gasket. 2 Install the transmission fluid pan bolts. ^ Tighten to 14 Nm (10 lb-ft). 4WD vehicles 13. Install the front driveshaft and align the index marks made during removal. Install the 4 bolts. ^ Tighten to 103 Nm (76 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4187 14. Install the front driveshaft shield and install the 2 nuts. ^ Tighten to 18 Nm (13 lb-ft). All vehicles 15. NOTE: Start by filling the transmission with 4.7L (5 qt) of clean transmission fluid. Fill the transmission to the correct level with clean transmission fluid. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4193 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4194 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4195 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4196 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4197 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4198 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4199 Brake Switch - TCC: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4200 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4201 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4202 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4203 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4204 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4205 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 4206 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations View 151-19 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4212 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4213 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4214 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4215 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4216 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4217 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4218 Overdrive Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4219 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4220 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4221 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4222 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4223 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4224 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4225 C2135 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4230 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4231 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4232 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4233 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4234 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4235 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4236 Throttle Position Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4237 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4238 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4239 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4240 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4241 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4242 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Mode Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4247 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4248 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4249 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4250 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4251 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4252 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4253 Transmission Mode Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4254 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4255 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4256 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4257 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4258 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4259 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4260 Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch Column Shift Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift Transmission Control (TC) Switch - Column Shift Removal and Installation NOTE: The transmission control (TC) switch is part of the transmission range selector lever. 1. To install a new TC switch, a new transmission range selector lever must be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch Column Shift > Page 4263 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Removal 1. Lift the center console lid cover and remove the console finish panel. 2. Depress the bottom of the button. Using a suitable tool, pry forward on the top of the selector lever button and remove the selector lever button. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch Column Shift > Page 4264 3. Remove the screw, slide the selector lever knob up and remove the selector lever knob. 4. Remove the selector lever knob shroud. 5. Disconnect the transmission control (TC) switch electrical connector, release the selector lever bezel locking tabs and remove the selector lever bezel from the selector lever. 6. Release the 2 tabs and push the TC switch through the selector lever bezel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch Column Shift > Page 4265 Installation 1. Install the TC switch in the selector lever bezel. 2. Install the selector lever bezel on the locking tabs and connect the TC switch electrical connector. 3. Install the selector lever knob shroud. 4. CAUTION: Do not overtighten the screw or damage to the selector lever knob can occur. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch Column Shift > Page 4266 Install the selector lever knob and install the screw. 5. Position the selector lever button in place and press in on the top of the selector lever button to install. 6. Install the center console finish panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4270 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4273 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4274 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4275 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4276 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4277 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4278 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4279 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4280 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4281 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4282 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4283 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4284 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4285 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4286 C167 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4287 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the selector lever cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 4. Loosen the digital transmission range (TR) sensor bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4288 5. NOTE: The manual control lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 lb-in). 7. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever shaft outer nut. ^ Tighten to 33 Nm (24 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4289 8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. With the manual control lever in overdrive connect the selector lever cable. 9. Lower the vehicle. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4290 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Removal NOTE: The manual control lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the selector lever cable. Disconnect the selector lever cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4291 3. Disconnect the digital transmission range (TR) electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4292 Installation 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4293 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 lb-ft). 5. Connect the digital TR sensor electrical connector. 6. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable end to the manual control lever with the lever in the (D) position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4294 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Locations Output Shaft Speed (OSS) Sensor View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4299 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4300 View 151-12 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4301 Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4302 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4305 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4306 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4307 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4308 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4309 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4310 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4311 Transmission Speed Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4312 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4313 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4314 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4315 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4316 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4317 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4318 Transmission Speed Sensor: Connector Views C193 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4319 C1107 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4320 C143 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 3. Remove the TSS sensor bolt and sensor. ^ Remove the TSS sensor bolt. ^ Remove the TSS sensor. 4. To install, reverse the removal procedure. ^ Tighten bolt to 11 Nm (8 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4323 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the output shaft speed (OSS) sensor electrical connector. 3. Remove the OSS sensor bolt and sensor. ^ Remove the OSS sensor bolt. ^ Remove the OSS sensor. 4. To install, reverse the removal procedure. ^ Tighten bolt to 12 Nm (9 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4328 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4329 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4330 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4331 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4332 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4333 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4334 Transmission Temperature Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4335 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4336 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4337 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4338 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4339 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4340 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Diagrams C2008 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Floor Shift Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Floor Shift Brake Shift Interlock Actuator - Floor Shift Brake Shift Interlock Actuator (BSIA) - Floor Shift Removal 1. Remove the floor console left side kick panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Floor Shift > Page 4347 2. Lift the console storage lid cover and remove the console finish panel. 3. Disconnect the selector lever cable from the arm of the selector lever. 4. Disconnect the selector lever cable from the selector lever cable bracket on the selector lever. 5. Remove the selector lever bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Floor Shift > Page 4348 6. Disconnect the selector lever electrical connector and remove the selector lever from the vehicle. 7. Disconnect the electrical connector. 1 Disconnect the overdrive cancel button electrical connector. 2 Cut the tie strap holding the wire harness to the base of the selector lever. 8. Remove the brake shift interlock actuator (BSIA). 1 Remove the bulb from the housing. 2 Cut the tie strap from the wire harness. 3 Remove the 2 screws and remove the BSIA. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Floor Shift > Page 4349 Installation 1. Install the BSIA. 1 Install the BSIA and install the 2 screws. 2 Install the bulb into the housing. 3 Install a new tie strap on the wire harness. 2. Connect the electrical connector. 1 Connect the overdrive cancel button electrical connector. 2 Install a new tie strap to the wire harness. 3. Position the selector lever assembly in the console and install the bolts. ^ Tighten to 12 Nm (9 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Floor Shift > Page 4350 4. Connect the selector lever electrical connector. 5. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable in the selector lever cable bracket. 6. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the selector lever arm. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Floor Shift > Page 4351 7. Install the console finish panel. 8. Install the left console kick panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Floor Shift > Page 4352 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the steering wheel. 3. Remove the 2 screws and the lower dash panel. 4. Remove the screw and the lower steering column shroud. 5. Remove the 2 screws and the upper steering column shroud. 6. Disconnect the clockspring electrical connectors. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Floor Shift > Page 4353 7. Remove the screw and slide the multi-function switch up and position it aside. 8. Place a piece of tape on the clockspring to prevent it from rotating. 9. Press the 3 tabs on the clockspring and slide the clockspring off. 10. Remove the 3 screws and remove the clockspring and shroud mounting bracket. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator - Floor Shift > Page 4354 11. Disconnect the brake shift interlock switch electrical connector. 12. Release the tab and slide the brake shift interlock down to remove. 13. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4359 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4360 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4361 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4362 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4363 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4364 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4365 Shift Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4366 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4367 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4368 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4369 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4370 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4371 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4372 Shift Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the shift solenoid operation information when carrying out Pinpoint Test A. See: Transmission Control Systems/Testing and Inspection/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4373 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always Off" Failed off due to PCM and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4374 Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Pinpoint Tests Refer to Vehicle/Diagrams for schematic and connector information. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Diagrams C3245 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Knob Shifter A/T: Service and Repair Selector Lever Knob Selector Lever Knob Selector Lever Knob Removal 1. Depress the bottom of the selector lever button. Using a suitable tool, pry forward on the top of the selector lever button and remove the selector lever button. 2. Remove the screw, slide the selector lever knob up and remove the selector lever knob. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Knob > Page 4380 Installation 1. CAUTION: Do not overtighten the screw or damage to the selector lever knob can occur. Position the selector lever knob on the selector lever and install the screw. 2. Position the selector lever button in place and press in on the top of the selector lever button to install. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Knob > Page 4381 Shifter A/T: Service and Repair Selector Lever Bezel Selector Lever Bezel Selector Lever Bezel Removal 1. Lift the center console lid cover and remove the console finish panel. 2. Depress the bottom of the button. Using a suitable tool, pry forward on the top of the selector lever button and remove the button. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Knob > Page 4382 3. Remove the screw, slide the selector lever knob up and remove the selector lever knob. 4. Remove the selector lever knob shroud. 5. Disconnect the transmission control (TC) switch electrical connector, release the selector lever bezel locking tabs and remove the selector lever bezel from the selector lever. 6. Release the 2 tabs and push the TC switch through the selector lever bezel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Knob > Page 4383 Installation 1. Install the TC switch in the selector lever bezel. 2. Install the selector lever bezel on the locking tabs and connect the TC switch electrical connector. 3. Install the selector lever knob shroud. 4. CAUTION: Do not overtighten the screw or damage to the selector lever knob can occur. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Knob > Page 4384 Install the selector lever knob and install the screw. 5. Position the selector lever button in place and press in on the top of the selector lever button to install. 6. Install the center console finish panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Knob > Page 4385 Shifter A/T: Service and Repair Selector Lever Button Selector Lever Button Selector Lever Button Removal 1. Depress the bottom of the button. Using a suitable tool, pry forward on the top of the selector lever button and remove the selector lever button. Installation 1. Position the selector lever button in place and press in on the top of the selector lever button to install. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Knob > Page 4386 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Knob > Page 4387 Shifter A/T: Service and Repair Selector Lever - Column Shift Selector Lever - Column Shift Removal 1. Remove the steering wheel. 2. Remove the screw and the lower steering column shroud. 3. Remove the 2 screws and the upper steering column shroud. 4. Disconnect the overdrive cancel switch electrical connector. 5. Remove the retaining screw and remove the selector lever. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Knob > Page 4388 Installation 1. Position the selector lever in the steering column and install the screw. ^ Tighten to 20 Nm (15 lb-ft). 2. CAUTION: Route the overdrive cancel switch wire harness carefully to prevent damage to the wire harness. Connect the overdrive cancel switch electrical connector. 3. Position the upper steering column shroud and install the 2 screws. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Knob > Page 4389 4. Position the lower steering column shroud and install the screw. 5. Install the steering wheel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Knob > Page 4390 Shifter A/T: Service and Repair Selector Lever - Floor Shift Selector Lever - Floor Shift Selector Lever - Floor Shift Removal 1. Remove the floor console left side kick panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Knob > Page 4391 2. Lift the console storage lid cover and remove the console finish panel. 3. Disconnect the selector lever cable from the arm of the selector lever. 4. Disconnect the selector lever cable from the selector lever cable bracket on the selector lever. 5. Remove the selector lever bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Knob > Page 4392 6. Disconnect the selector lever electrical connector and remove the selector lever from the vehicle. Installation 1. Position the selector lever assembly in the console and install the bolts. ^ Tighten to 12 Nm (9 lb-ft). 2. Connect the selector lever harness electrical connector. 3. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Knob > Page 4393 back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable in the selector lever cable bracket. 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the selector lever arm. 5. Install the console finish panel. 6. Install the left console kick panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable - Floor Shift Shift Cable: Service and Repair Selector Lever Cable - Floor Shift Selector Lever Cable - Floor Shift Selector Lever Cable - Floor Shift, 4.2L Engine Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable - Floor Shift > Page 4399 Selector Lever Cable - Floor Shift, 4.6L And 5.4L Engines Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the left console kick panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable - Floor Shift > Page 4400 3. Lift the console storage lid and remove the console finish panel. 4. Disconnect the selector lever cable from the selector lever arm. 5. Disconnect the selector lever cable from the selector lever bracket. 6. Push the rubber grommet and selector lever cable through the floor panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable - Floor Shift > Page 4401 7. Disconnect the electrical connector from the selector lever cable bracket. 8. Disconnect the selector lever cable from the transmission. 1 Unlock the selector lever cable adjustment lock by rotating the lock upward and remove the selector lever cable from the manual control lever. 2 Disconnect the selector lever cable from the selector lever cable bracket. Vehicles equipped with 4.6/5.4L engines 9. If necessary, remove the 2 bolts and the selector lever cable bracket. Vehicles equipped with 4.2L engines Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable - Floor Shift > Page 4402 10. If necessary, remove the selector lever cable bracket. 1 Remove the bolt. 2 Remove the nut. Installation Vehicles equipped with 4.6/5.4L engines 1. If removed, position the selector lever cable bracket and install the 2 bolts. ^ Tighten to 25 Nm (18 lb-ft). Vehicles equipped with 4.2L engine 2. If removed, install the selector lever cable bracket. 1 Install the bolt. ^ Tighten to 40 Nm (30 lb-ft). 2 Install the nut. ^ Tighten to 40 Nm (30 lb-ft). All vehicles 3. Push the rubber grommet and selector lever cable through the floor panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable - Floor Shift > Page 4403 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the selector lever bracket. 5. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the selector lever arm. 6. Place the selector lever in the 1st position toward the rear of the vehicle. 7. Move the selector lever forward 2 detents. This should be the (D) position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable - Floor Shift > Page 4404 8. Rotate the manual control lever forward until the travel stops. Then rotate the manual control lever back 2 detents to the (D) position. 9. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the selector lever cable bracket. Connect the selector lever cable to the manual control lever. 1 Install the new selector lever cable retainer. 2 Connect the selector lever cable to the selector lever cable bracket and rotate the lock downward to lock the adjuster. 10. Connect the electrical connector to the selector lever cable bracket. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable - Floor Shift > Page 4405 11. Verify that the engine will start in PARK and NEUTRAL. Verify that the reverse lamps will illuminate in the REVERSE position. If not, check the adjustment of the transmission range (TR) sensor. 12. Adjust the selector lever cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable - Floor Shift > Page 4406 Shift Cable: Service and Repair Selector Lever Cable - Column Shift Selector Lever Cable - Column Shift Selector Lever Cable - Column Shift, 4.2L Engine Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable - Floor Shift > Page 4407 Selector Lever Cable - Column Shift, 4.6L And 5.4L Engines Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the electrical connector from the selector lever cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable - Floor Shift > Page 4408 3. NOTE: The 4.6/5.4L shown, 4.2L similar. Disconnect the selector lever cable from the transmission. 1 Disconnect the selector lever cable from the manual control lever. 2 Disconnect the selector lever cable from the selector lever cable bracket. 4. Remove the selector lever cable from the routing clip. Vehicles equipped with 4.6/5.4L engines 5. If necessary, remove the bolts and the selector lever cable bracket from the transmission. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable - Floor Shift > Page 4409 Vehicles equipped with 4.2L engines 6. If necessary, remove the selector lever cable bracket. 1 Remove the bolt. 2 Remove the nut. All vehicles 7. Remove the 2 screws and the lower dash panel. 8. Disconnect the selector lever cable from the steering column. 1 Disconnect the selector lever cable from the transmission selector lever arm and support. 2 Disconnect the selector lever cable from the steering column bracket. 3 Remove and discard the selector lever cable retainer. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable - Floor Shift > Page 4410 9. Use a suitable tool to push the rubber grommet through the bulkhead. 10. From the passenger compartment, remove the selector lever cable from the vehicle. Installation All vehicles 1. From inside the vehicle, feed the selector lever cable through the opening in the bulkhead and downward toward the transmission. 2. Seat the selector lever cable rubber grommet in the bulkhead opening. 3. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the steering column. 1 Install the new selector lever cable retainer. 2 Connect the selector lever cable to the steering column bracket. 3 Connect the selector lever cable to the transmission selector lever arm and support. 4. Place the selector lever in the (D) position. 5. Hang a 1.4 kg (3 lb) weight on the selector lever. 6. Rotate the manual control lever forward until the travel stops. Then rotate the manual lever back 2 detents to the (D) position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable - Floor Shift > Page 4411 Vehicles equipped with 4.6/5.4L engines 7. If removed, position the selector lever cable bracket and install the 2 bolts. ^ Tighten to 25 Nm (18 lb-ft). Vehicles equipped with 4.2L engines 8. Install the selector lever cable bracket. 1 Install the bolt. ^ Tighten to 40 Nm (30 lb-ft). 2 Install the nut. ^ Tighten to 40 Nm (30 lb-ft). All vehicles 9. NOTE: The 4.6/5.4L shown, 4.2L similar. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the selector lever cable bracket. Do not connect the selector lever cable to the manual control lever at this time. 10. Connect the electrical connector to the selector lever bracket. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable - Floor Shift > Page 4412 11. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the manual control lever and lock the adjuster. 12. CAUTION: Failure to route the selector lever cable in the routing clip can allow the cable to rest on exhaust components causing damage to the cable. Route the selector lever cable in the routing clip. 13. Verify the vehicle will start in PARK and NEUTRAL. Verify the reverse lamps illuminate in the REVERSE position. If not, check the adjustment of the transmission range (TR) sensor. 14. Install the 2 screws and the lower dash panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable - Floor Shift > Page 4413 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4418 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4419 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4420 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4421 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4422 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4423 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4424 Throttle Position Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4425 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4426 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4427 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4428 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4429 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4430 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation Torque Converter: Description and Operation Torque Converter The torque converter transmits and multiplies torque. The torque converter is a 4-element device: ^ Impeller assembly ^ Turbine assembly ^ Reactor assembly ^ Clutch and damper assembly The standard torque converter components operate as follows: ^ Rotation of the converter housing and impeller set the transmission fluid in motion. ^ The turbine reacts to the transmission fluid motion from the impeller, transferring rotation to the geartrain through the input shaft. ^ The reactor redirects transmission fluid going back into the impeller, allowing for torque multiplication. ^ The clutch and damper assembly dampens powertrain torsional vibration and provides a direct mechanical connection for improved efficiency. ^ Power is transmitted from the torque converter to the planetary gearsets and other components through the input shaft. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Stall Speed Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Stall Speed > Page 4436 Torque Converter: Testing and Inspection Torque Converter Diagnosis Torque Converter Diagnosis Prior to installing new or remanufactured torque converters, all diagnostic procedures must be followed. This is to prevent the unnecessary installation of new or remanufactured torque converters. Only after a complete diagnostic evaluation can the decision be made to install a new or remanufactured torque converter. Begin with the normal diagnostic procedures as follows: 1. Preliminary inspection. 2. Know and understand the customer's concern. 3. Verify the condition - carry out the torque converter operation test. 4. Carry out diagnostic procedures. ^ Carry out on-board diagnostics. Repair all non-transmission related DTCs first. - Repair all transmission DTCs. - Rerun on-board diagnostic to verify repair. ^ Carry out Line Pressure Test. See: Transmission Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Special Testing Procedures ^ Carry out Stall Speed Test. See: Transmission Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Special Testing Procedures ^ Carry out Diagnostic Routines. Refer to Diagnosis By Symptom. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms Use the Diagnosis by Symptom 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 repair as required before changing the torque converter. Torque Converter Operation Test This test verifies that the torque converter clutch control system and the torque converter are operating correctly. 1. Carry out Quick Test with scan tool. Refer to Computers and Control Systems. Check for DTCs. 2. Connect a tachometer to the engine. 3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds for approximately 15 minutes in (D) position. 4. After normal operating temperature is reached, maintain a constant vehicle speed of about 80 km/h (50 mph) and tap brake pedal with the left foot. 5. Engine rpm should increase when brake pedal is tapped and decrease about 5 seconds after pedal is released. If this does not occur, see torque converter operation concerns. Refer to Diagnosis By Symptom. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms 6. If the vehicle stalls in (D) or MANUAL 2 at idle with vehicle at a stop, move the selector lever to MANUAL 1 position. If the vehicle stalls, see torque converter operation concerns. Refer to Diagnosis By Symptom. If the vehicle does not stall in (D), refer to Diagnosis By Symptom. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms 7. If the vehicle exhibits a vibration during the road test, complete the Road Test Evaluation Form. This form will aid the technician in determining the source of the vibration. NOTE: The following is a list of common vehicle concerns that have been misdiagnosed as torque converter clutch shudder. ^ Spark plugs - check for cracks, high resistance or broken insulators. ^ Plug wires. ^ Fuel injector - filter may be plugged. ^ Fuel contamination - engine runs poor. ^ EGR valve - valve may let in too much exhaust gas and cause engine to run lean. ^ Vacuum leak - engine will not get correct air/fuel mixture. ^ Manifold absolute pressure (MAP)/mass air flow (MAF) sensor - incorrect air/fuel mixture. ^ Heated oxygen sensor (HO2S) - too rich/lean air/fuel mixture. ^ Fuel pressure - may be too low. ^ Engine mounts - loose/damaged mounts can cause vibration concerns. ^ Axle joints - check for vibration. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Stall Speed > Page 4437 Torque Converter Road Evaluation Form (Part 1) Torque Converter Road Evaluation Form (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Stall Speed > Page 4438 Torque Converter: Testing and Inspection Torque Converter Torque Converter 1. A new or remanufactured torque converter must be installed if one or more of the following statements is true: ^ A torque converter malfunction has been determined based on complete diagnostic procedures. ^ Converter stud or studs, impeller hub or bushing are damaged. ^ Discoloration (due to overheating). ^ Evidence of transmission assembly or transmission fluid contamination due to the following transmission or converter failure modes: Major metallic failure. - Multiple clutches or clutch plate failures. - Sufficient component wear which results in metallic contamination. - Internal torque converter contamination present. For additional information, refer to Torque Converter Contamination Inspection. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Stall Speed > Page 4439 Torque Converter: Testing and Inspection Torque Converter Contamination Inspection Torque Converter Contamination Inspection CAUTION: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission and converter being serviced. CAUTION: The torque converter drain plug and seal are not reusable. If equipped, discard the drain plug and seal, then install a new drain plug assembly. 1. If a new or remanufactured torque converter is not being installed, the following steps must be completed. 2. With the torque converter on a bench, pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter and examine the transmission fluid. 3. Observe the color and odor of the transmission fluid. The transmission fluid should be red, not brown or black. Odor may indicate an overheating condition such as clutch disc or band failure. 4. Examine the stain on the tissue for evidence of particles (spec of any kind). Examine the transmission fluid level indicator for signs of antifreeze (gum or varnish). If particles are present in the transmission fluid or there is evidence of engine coolant or water, a new torque converter must be installed. 5. If there are no particles or contamination present, drain the remainder of the transmission fluid from the torque converter. 6. Add 1.9L (2 qt) of clean transmission fluid into the converter and agitate by hand. 7. Thoroughly drain the transmission fluid. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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: > 09-20-14 > Oct > 09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift Torque Converter Clutch: Customer Interest A/T - Uncommanded TCC Lock Up On 1-2 Upshift TSB 09-20-14 10/19/09 UN-COMMANDED TCC APPLY ON THE 1-2 SHIFT CAUSING PERCEPTION OF HESITATION AND/OR LACK OF POWER DURING SHIFT FORD: 2005-2010 Crown Victoria 2005-2006 Expedition 2005-2010 E-150, E-250, E-350, F-150 LINCOLN: 2005-2010 Town Car 2006-2008 Mark LT MERCURY: 2005-2010 Grand Marquis This article supersedes TSB 6-22-7 to update the Issue Statement, vehicle model years and model line covered. ISSUE Some 2005-2010 vehicles equipped with a 4R70/75E-W transmission may experience an un-commanded torque converter clutch (TCC) apply or TCC partial apply immediately after the 1-2 shift. This may result in the perception that the vehicle lacks power or that the transmission is up-shifting too early. Additional symptoms of uncommanded TCC apply when coming to a stop (before the 2-1 downshift is commanded), are engine stalling or lugging when engaging manual 2nd while at a stop and code P1742 may be present in continuous memory. However, the vehicle should operate normally in park, reverse, neutral and manual 1st gear. ACTION Follow the Service Procedure for verification and repair. SERVICE PROCEDURE 1. Monitor (TCC %) solenoid command state - duty cycle and (TC SLIP ACT) torque converter clutch slippage - RPM, while in 2nd, 3rd or 4th gear with a TCC % reading 0. a. If TCC % = 0 and TC SLIP ACT = less than 20 RPM then inspect the number 7 check ball in the main control valve body for damage. Replace as required following the appropriate Workshop Manual (WSM) under Disassembly and Assembly of Subassemblies - Main Control Valve Body. (Figure 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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: > 09-20-14 > Oct > 09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift > Page 4448 NOTE THIS PROCEDURE IS PERFORMED IN 2ND GEAR AUTO (NOT MANUAL 2). MONITOR (TC SLIP ACT) AFTER THE POWERTRAIN CONTROL MODULE (PCM) COMMANDS 2ND GEAR AND BEFORE THE VEHICLE SPEED SENSOR (VSS) READS 35 MPH (56 KM/H). b. If you receive any other reading, this procedure does not apply; follow normal diagnostic procedures as outlined in the appropriate WSM. NOTE IT IS NORMAL FOR THE PCM TO COMMAND 4TH GEAR AT SPEEDS AS LOW AS 19 MPH (30 KM/H) WITH LIGHT ACCELERATION WHEN THE THROTTLE POSITION IS LESS THEN 20%. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092014A 2005-2010 Crown Victoria, 2.3 Hrs. Grand Marquis, Town Car, Econoline 150/250/350, 2005-2006 Expedition: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) 092014A 2005-2010 F-150, 2.2 Hrs. 2006-2008 Mark LT: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7E195 01 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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: > 09-20-14 > Oct > 09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift Torque Converter Clutch: All Technical Service Bulletins A/T - Uncommanded TCC Lock Up On 1-2 Upshift TSB 09-20-14 10/19/09 UN-COMMANDED TCC APPLY ON THE 1-2 SHIFT CAUSING PERCEPTION OF HESITATION AND/OR LACK OF POWER DURING SHIFT FORD: 2005-2010 Crown Victoria 2005-2006 Expedition 2005-2010 E-150, E-250, E-350, F-150 LINCOLN: 2005-2010 Town Car 2006-2008 Mark LT MERCURY: 2005-2010 Grand Marquis This article supersedes TSB 6-22-7 to update the Issue Statement, vehicle model years and model line covered. ISSUE Some 2005-2010 vehicles equipped with a 4R70/75E-W transmission may experience an un-commanded torque converter clutch (TCC) apply or TCC partial apply immediately after the 1-2 shift. This may result in the perception that the vehicle lacks power or that the transmission is up-shifting too early. Additional symptoms of uncommanded TCC apply when coming to a stop (before the 2-1 downshift is commanded), are engine stalling or lugging when engaging manual 2nd while at a stop and code P1742 may be present in continuous memory. However, the vehicle should operate normally in park, reverse, neutral and manual 1st gear. ACTION Follow the Service Procedure for verification and repair. SERVICE PROCEDURE 1. Monitor (TCC %) solenoid command state - duty cycle and (TC SLIP ACT) torque converter clutch slippage - RPM, while in 2nd, 3rd or 4th gear with a TCC % reading 0. a. If TCC % = 0 and TC SLIP ACT = less than 20 RPM then inspect the number 7 check ball in the main control valve body for damage. Replace as required following the appropriate Workshop Manual (WSM) under Disassembly and Assembly of Subassemblies - Main Control Valve Body. (Figure 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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: > 09-20-14 > Oct > 09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift > Page 4454 NOTE THIS PROCEDURE IS PERFORMED IN 2ND GEAR AUTO (NOT MANUAL 2). MONITOR (TC SLIP ACT) AFTER THE POWERTRAIN CONTROL MODULE (PCM) COMMANDS 2ND GEAR AND BEFORE THE VEHICLE SPEED SENSOR (VSS) READS 35 MPH (56 KM/H). b. If you receive any other reading, this procedure does not apply; follow normal diagnostic procedures as outlined in the appropriate WSM. NOTE IT IS NORMAL FOR THE PCM TO COMMAND 4TH GEAR AT SPEEDS AS LOW AS 19 MPH (30 KM/H) WITH LIGHT ACCELERATION WHEN THE THROTTLE POSITION IS LESS THEN 20%. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092014A 2005-2010 Crown Victoria, 2.3 Hrs. Grand Marquis, Town Car, Econoline 150/250/350, 2005-2006 Expedition: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) 092014A 2005-2010 F-150, 2.2 Hrs. 2006-2008 Mark LT: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7E195 01 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4459 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4460 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4461 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4462 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4463 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4464 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4465 Torque Converter Clutch Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4466 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4467 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4468 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4469 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4470 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4471 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Mechanical Specifications Transmission Cooler: Mechanical Specifications Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Mechanical Specifications > Page 4476 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Mechanical Specifications > Page 4477 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 4478 Transmission Cooler: Locations Transmission With an Auxiliary Transmission Fluid Cooler Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 4479 Transmission Without an Auxiliary Transmission Fluid Cooler Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Transmission Cooler: Initial Inspection and Diagnostic Overview Inspection and Verification CAUTION: When internal wear/damage occurs in the transmission, metal particles, clutch plate material and band material can travel into the torque converter, the transmission fluid cooler tubes, the in-tank transmission fluid cooler and the auxiliary transmission fluid cooler, if so equipped. These contaminants are a major cause of recurring transmission concerns. To prevent future concerns, remove these contaminants from the cooling system before placing the transmission back into use. Refer to transmission fluid cooler flow testing, backflushing and cleaning, torque converter cleaning and inspection and flushing. 1. Visually inspect for obvious signs of mechanical damage, incorrect component installation and system leaks. Repair as necessary. ^ Install a new or remanufactured radiator when transmission fluid is found leaking from the intank transmission fluid cooler. ^ Install a new auxiliary transmission fluid cooler if there is leakage from the auxiliary transmission fluid cooler. 2. If the fault is not visually evident, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures/Symptom Chart - Transmission Cooling Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4482 Transmission Cooler: Symptom Related Diagnostic Procedures Symptom Chart - Transmission Cooling Symptom Chart - Noise, Vibration and Harshness (NVH) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4483 Transmission Cooler: Component Tests and General Diagnostics Transmission Fluid Cooler Transmission Fluid Cooler CAUTION: Whenever a transmission has been disassembled to install new parts, the transmission fluid cooler tubes and the in-tank cooler if equipped must be cleaned and backflushed. Use a suitable torque converter/fluid cooler cleaner. NOTE: If the vehicle is equipped with a oil-to-air (OTA) cooler, a new OTA must be installed. NOTE: Cleaning and backflushing the transmission fluid cooling system along with following all the normal cleaning and inspection procedures during disassembly and reassembly will keep contamination from reentering the transmission and causing a repeat repair. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the torque converter and transmission fluid cooler. These contaminants are a major cause of recurring transmission troubles and must be removed from the system before the transmission is put back into use. Transmission Fluid Cooler Flow Test NOTE: The transmission linkage/cable adjustment, transmission fluid level and line pressure must be within specification before carrying out this test. 1. Remove transmission fluid level indicator from transmission fluid filler tube. 2. Place funnel in transmission fluid filler tube. 3. Position the vehicle on a hoist. 4. Remove the cooler return tube (top fitting) from the fitting on the transmission case. 5. Connect one end of a hose to the cooler return tube and route the other end of the hose up to a point where it can be inserted into the funnel at the transmission fluid filler tube. 6. Remove the safety stands and lower the vehicle. Insert end of hose into the funnel. 7. Start the engine and run it at idle with the transmission in NEUTRAL. 8. When transmission fluid flows from the hose in a steady stream, a liberal amount of transmission fluid should be observed. "Liberal" is about 1L (1 qt) delivered in 15 seconds. If a liberal flow is observed, the test is complete. 9. If the flow is not liberal, stop the engine. Disconnect the hose from the cooler return tube and connect it to the converter outlet fitting (bottom fitting) on the transmission case. 10. Repeat Steps 6 and 7. If flow is now approximately 1L (1 qt) in 15 seconds, refer to Transmission Fluid Cooler Backflushing and Cleaning. If the flow is still not approximately 1L (1 qt) in 15 seconds, repair or install pump and or converter. Water in Transmission Fluid To correctly repair an automatic transmission or transaxle that has had water or coolant introduced into the system, completely disassemble, clean and replace the following parts: ^ All internal and external seals ^ All friction material; clutches and bands ^ Torque converter ^ All parts with bonded seals ^ All solenoids ^ All transmission fluid filters Prior to installing the transmission or transaxle, the transmission fluid cooler(s), transmission fluid cooler tubes and transmission fluid cooler hoses need to be flushed and cleaned. Transmission Fluid Cooler Leaks at Radiator Transmission Fluid Cooler Leaks at Radiator Transmission fluid may leak between the radiator transmission fluid cooler and the transmission fluid cooler fitting (not the transmission fluid cooler tube into the transmission fluid cooler fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission fluid cooler fitting. Insufficient thread sealer on the transmission fluid cooler fitting may cause this. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures Transmission Cooler: Procedures Transmission Fluid Cooler Backflushing and Cleaning 1. CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail; this will effect the operation of the transmission. Conduct backflushing with a suitable torque converter/fluid cooler cleaner. Test your equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new filter in the flush equipment if flow is weak or contaminated. 2. If equipped, remove and discard the transmission fluid in-line filter. 3. Remove the transmission fluid cooler bypass valve and install rubber hoses in its place. 4. To aid in attaching the cleaner to the transmission steel cooler tubes, connect 2 additional rubber hoses to the transmission end of the steel transmission cooler tubes. ^ Connect the cleaner tank pressure tubes to the steel transmission cooler return tubes (longest tube). ^ Connect a tank return hose to the steel transmission cooler pressure tubes (shorter tube). Place the outlet end of this hose in the tank reservoir. 5. Turn on the pump and allow the transmission fluid to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in cooler system). 6. Switch off the pump and disconnect the pressure hose from the transmission cooler return tube. 7. Use compressed air to blow out the cooler(s) and tubes (blow air into the transmission cooler return tubes) until all fluid is removed. 8. Remove the rubber return hose from the remaining steel cooler tube. 9. Remove the rubber hoses and reinstall the transmission fluid cooler bypass valve. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 4486 Transmission Cooler: Removal and Replacement Transmission Fluid Cooler Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 3 pushpins and position the air deflector aside. 3. Using the special tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler. 4. Remove the 2 bolts and remove the transmission fluid cooler. ^ To install, tighten to 15 Nm (11 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 4487 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Mode Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4495 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4496 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4497 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4498 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4499 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4500 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4501 Transmission Mode Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4502 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4503 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4504 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4505 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4506 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4507 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4508 Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift Transmission Control (TC) Switch - Column Shift Removal and Installation NOTE: The transmission control (TC) switch is part of the transmission range selector lever. 1. To install a new TC switch, a new transmission range selector lever must be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 4511 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Removal 1. Lift the center console lid cover and remove the console finish panel. 2. Depress the bottom of the button. Using a suitable tool, pry forward on the top of the selector lever button and remove the selector lever button. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 4512 3. Remove the screw, slide the selector lever knob up and remove the selector lever knob. 4. Remove the selector lever knob shroud. 5. Disconnect the transmission control (TC) switch electrical connector, release the selector lever bezel locking tabs and remove the selector lever bezel from the selector lever. 6. Release the 2 tabs and push the TC switch through the selector lever bezel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 4513 Installation 1. Install the TC switch in the selector lever bezel. 2. Install the selector lever bezel on the locking tabs and connect the TC switch electrical connector. 3. Install the selector lever knob shroud. 4. CAUTION: Do not overtighten the screw or damage to the selector lever knob can occur. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 4514 Install the selector lever knob and install the screw. 5. Position the selector lever button in place and press in on the top of the selector lever button to install. 6. Install the center console finish panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair Transmission Mount: Service and Repair Transmission Insulator and Retainer Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the transfer case skid plate. 3. Remove the 2 bolts for the exhaust hanger. 4. Remove the rear transmission insulator nuts. 5. Install a suitable transmission jack. 6. Slightly raise the rear of the transmission and remove the bolts. Remove the rear transmission insulator. Installation 1. Install the transmission insulator and the bolts. ^ Tighten to 80 Nm (59 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Page 4518 2. Lower the transmission onto the crossmember and install the nuts. ^ Tighten to 103 Nm (76 lb-ft). 3. Install the bolts retaining the exhaust hanger to the crossmember. ^ Tighten to 40 Nm (30 lb-ft). 4. If equipped, install the transfer case skid plate. ^ Tighten to 48 Nm (35 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4522 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4525 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4526 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4527 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4528 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4529 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4530 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4531 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4532 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4533 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4534 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4535 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4536 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4537 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4538 C167 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4539 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the selector lever cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 4. Loosen the digital transmission range (TR) sensor bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4540 5. NOTE: The manual control lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 lb-in). 7. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever shaft outer nut. ^ Tighten to 33 Nm (24 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4541 8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. With the manual control lever in overdrive connect the selector lever cable. 9. Lower the vehicle. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4542 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Removal NOTE: The manual control lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the selector lever cable. Disconnect the selector lever cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4543 3. Disconnect the digital transmission range (TR) electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4544 Installation 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4545 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 lb-ft). 5. Connect the digital TR sensor electrical connector. 6. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable end to the manual control lever with the lever in the (D) position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4546 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Locations Output Shaft Speed (OSS) Sensor View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4551 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4552 View 151-12 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4553 Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4554 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4557 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4558 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4559 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4560 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4561 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4562 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4563 Transmission Speed Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4564 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4565 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4566 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4567 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4568 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4569 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4570 Transmission Speed Sensor: Connector Views C193 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4571 C1107 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4572 C143 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 3. Remove the TSS sensor bolt and sensor. ^ Remove the TSS sensor bolt. ^ Remove the TSS sensor. 4. To install, reverse the removal procedure. ^ Tighten bolt to 11 Nm (8 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4575 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the output shaft speed (OSS) sensor electrical connector. 3. Remove the OSS sensor bolt and sensor. ^ Remove the OSS sensor bolt. ^ Remove the OSS sensor. 4. To install, reverse the removal procedure. ^ Tighten bolt to 12 Nm (9 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4580 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4581 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4582 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4583 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4584 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4585 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4586 Transmission Temperature Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4587 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4588 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4589 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4590 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4591 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4592 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 09-20-14 > Oct > 09 > A/T Uncommanded TCC Lock Up On 1-2 Upshift Valve Body: Customer Interest A/T - Uncommanded TCC Lock Up On 1-2 Upshift TSB 09-20-14 10/19/09 UN-COMMANDED TCC APPLY ON THE 1-2 SHIFT CAUSING PERCEPTION OF HESITATION AND/OR LACK OF POWER DURING SHIFT FORD: 2005-2010 Crown Victoria 2005-2006 Expedition 2005-2010 E-150, E-250, E-350, F-150 LINCOLN: 2005-2010 Town Car 2006-2008 Mark LT MERCURY: 2005-2010 Grand Marquis This article supersedes TSB 6-22-7 to update the Issue Statement, vehicle model years and model line covered. ISSUE Some 2005-2010 vehicles equipped with a 4R70/75E-W transmission may experience an un-commanded torque converter clutch (TCC) apply or TCC partial apply immediately after the 1-2 shift. This may result in the perception that the vehicle lacks power or that the transmission is up-shifting too early. Additional symptoms of uncommanded TCC apply when coming to a stop (before the 2-1 downshift is commanded), are engine stalling or lugging when engaging manual 2nd while at a stop and code P1742 may be present in continuous memory. However, the vehicle should operate normally in park, reverse, neutral and manual 1st gear. ACTION Follow the Service Procedure for verification and repair. SERVICE PROCEDURE 1. Monitor (TCC %) solenoid command state - duty cycle and (TC SLIP ACT) torque converter clutch slippage - RPM, while in 2nd, 3rd or 4th gear with a TCC % reading 0. a. If TCC % = 0 and TC SLIP ACT = less than 20 RPM then inspect the number 7 check ball in the main control valve body for damage. Replace as required following the appropriate Workshop Manual (WSM) under Disassembly and Assembly of Subassemblies - Main Control Valve Body. (Figure 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 09-20-14 > Oct > 09 > A/T Uncommanded TCC Lock Up On 1-2 Upshift > Page 4601 NOTE THIS PROCEDURE IS PERFORMED IN 2ND GEAR AUTO (NOT MANUAL 2). MONITOR (TC SLIP ACT) AFTER THE POWERTRAIN CONTROL MODULE (PCM) COMMANDS 2ND GEAR AND BEFORE THE VEHICLE SPEED SENSOR (VSS) READS 35 MPH (56 KM/H). b. If you receive any other reading, this procedure does not apply; follow normal diagnostic procedures as outlined in the appropriate WSM. NOTE IT IS NORMAL FOR THE PCM TO COMMAND 4TH GEAR AT SPEEDS AS LOW AS 19 MPH (30 KM/H) WITH LIGHT ACCELERATION WHEN THE THROTTLE POSITION IS LESS THEN 20%. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092014A 2005-2010 Crown Victoria, 2.3 Hrs. Grand Marquis, Town Car, Econoline 150/250/350, 2005-2006 Expedition: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) 092014A 2005-2010 F-150, 2.2 Hrs. 2006-2008 Mark LT: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7E195 01 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 09-20-14 > Oct > 09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift Valve Body: All Technical Service Bulletins A/T - Uncommanded TCC Lock Up On 1-2 Upshift TSB 09-20-14 10/19/09 UN-COMMANDED TCC APPLY ON THE 1-2 SHIFT CAUSING PERCEPTION OF HESITATION AND/OR LACK OF POWER DURING SHIFT FORD: 2005-2010 Crown Victoria 2005-2006 Expedition 2005-2010 E-150, E-250, E-350, F-150 LINCOLN: 2005-2010 Town Car 2006-2008 Mark LT MERCURY: 2005-2010 Grand Marquis This article supersedes TSB 6-22-7 to update the Issue Statement, vehicle model years and model line covered. ISSUE Some 2005-2010 vehicles equipped with a 4R70/75E-W transmission may experience an un-commanded torque converter clutch (TCC) apply or TCC partial apply immediately after the 1-2 shift. This may result in the perception that the vehicle lacks power or that the transmission is up-shifting too early. Additional symptoms of uncommanded TCC apply when coming to a stop (before the 2-1 downshift is commanded), are engine stalling or lugging when engaging manual 2nd while at a stop and code P1742 may be present in continuous memory. However, the vehicle should operate normally in park, reverse, neutral and manual 1st gear. ACTION Follow the Service Procedure for verification and repair. SERVICE PROCEDURE 1. Monitor (TCC %) solenoid command state - duty cycle and (TC SLIP ACT) torque converter clutch slippage - RPM, while in 2nd, 3rd or 4th gear with a TCC % reading 0. a. If TCC % = 0 and TC SLIP ACT = less than 20 RPM then inspect the number 7 check ball in the main control valve body for damage. Replace as required following the appropriate Workshop Manual (WSM) under Disassembly and Assembly of Subassemblies - Main Control Valve Body. (Figure 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 09-20-14 > Oct > 09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift > Page 4607 NOTE THIS PROCEDURE IS PERFORMED IN 2ND GEAR AUTO (NOT MANUAL 2). MONITOR (TC SLIP ACT) AFTER THE POWERTRAIN CONTROL MODULE (PCM) COMMANDS 2ND GEAR AND BEFORE THE VEHICLE SPEED SENSOR (VSS) READS 35 MPH (56 KM/H). b. If you receive any other reading, this procedure does not apply; follow normal diagnostic procedures as outlined in the appropriate WSM. NOTE IT IS NORMAL FOR THE PCM TO COMMAND 4TH GEAR AT SPEEDS AS LOW AS 19 MPH (30 KM/H) WITH LIGHT ACCELERATION WHEN THE THROTTLE POSITION IS LESS THEN 20%. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092014A 2005-2010 Crown Victoria, 2.3 Hrs. Grand Marquis, Town Car, Econoline 150/250/350, 2005-2006 Expedition: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) 092014A 2005-2010 F-150, 2.2 Hrs. 2006-2008 Mark LT: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7E195 01 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4608 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4609 Valve Body: Diagrams Main Control Valve Body Disassembled View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4610 Main Control Valve Body Disassembled View (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement Valve Body: Removal and Replacement Main Control Valve Body Removal 1. Drain transmission fluid and remove the transmission fluid pan and filter. 2. CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. 1 Disconnect the shift solenoid SSA and SSB. 2 Disconnect the torque converter clutch (TCC). 3 Disconnect the electronic pressure control (EPC) solenoid. 4 Disconnect the bulkhead inter-connector. 3. Remove the manual control valve detent lever bolt and spring. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4613 4. Remove the 24 valve body-to-case bolts and the EPC bracket bolt. 5. Remove the main control valve body and discard the pump outlet screen. Installation 1. NOTE: Make sure that the drive pin of the manual valve detent lever assembly engages the manual valve in the correct location prior to installing the bolts. Position the main control valve body gasket and main control valve body using 2 bolts as a guide. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4614 2. NOTE: The main control valve body bolts will be tightened in later steps. Loosely install the 11 long main control valve body bolts. 3. NOTE: The main control valve body bolts will be tightened in later steps. Loosely install the 12 short main control valve body bolts. 4. NOTE: Lubricate the EPC solenoid O-rings with clean transmission fluid. Position the EPC solenoid bracket and loosely install the bolt. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4615 5. Install the manual control valve detent lever spring and loosely install the bolt. 6. Tighten the bolts in the sequence shown. ^ Tighten to 10 Nm (89 lb-in). 7. Inspect the molded lead frame for damage. ^ Using the special tool, check all molded lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool easily passes through any molded lead frame connector pins or does not feel like it makes a good contact, install a new molded lead frame. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4616 8. Connect the molded lead frame to the solenoids. ^ Connect the bulkhead inter-connector by pressing it in place by hand and fully seating the connector in place. ^ Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. ^ Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. ^ Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 9. Install the transmission filter and pan. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4617 Valve Body: Overhaul Main Control Valve Body Disassembly Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4618 Main Control Valve Body Disassembled View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4619 Main Control Valve Body Disassembled View (Part 2) 1. Remove the torque converter clutch (TCC) solenoid and the shift solenoid. 1 Remove the retaining bolt. 2 Remove the shift solenoid. 3 Remove the TCC solenoid. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4620 2. Remove the 2 reinforcement plate and bolts. 3. Remove the separator plate and discard the gaskets. 4. NOTE: Note the location of the eight coasting booster valve shuttle balls for assembly. Remove the 8 coasting booster valve shuttle balls. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4621 Part 1 Part 2 5. Remove the converter drain back valve and solenoid pressure supply screen. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4622 6. Remove the main control valve body cover plate. 1 Remove the 13 main control valve body cover plate bolts. 2 Remove the main control valve body cover plate. Assembly CAUTION: Before beginning assembly, carry out and inspect the following: When building up subassemblies and assembling the transmission, ALWAYS use new gaskets and seals. All fasteners must be tightened to the torque specification indicated. In addition to appearing in the section, the necessary torque measurements can be found in the General Specifications Chart. When building up subassemblies, each component part should be lubricated with clean transmission fluid. It is also good practice to lubricate the subassemblies as they are installed in the case. Needle bearings, thrust washers and seals should be lightly coated with clean transmission fluid during subassembly buildup or transmission assembly. Many components and surfaces in the transmission are precision machined. Careful handling during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to machined surfaces. NOTE: Inspect the shift solenoid O-rings and TCC solenoid O-rings for damage. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4623 1. Install the valve body cover plate. 1 Position the valve body cover plate gasket and cover plate. 2 Loosely install the 2 guide pin bolts. 3 Loosely install the remaining bolts. 2. Tighten all the bolts in the sequence shown. ^ Tighten to 10 Nm (89 lb-in). 3. Install the 8 coasting booster valve shuttle balls. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4624 4. Install the converter drain back valve and solenoid pressure supply screen. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4625 5. Install the separator plate and gaskets. 6. Install the 2 reinforcement plate and bolts. ^ Tighten to 10 Nm (89 lb-in). 7. Install the shift solenoid. 1 Position the TCC solenoid. 2 Position the shift solenoid. 3 Install the bolt. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4626 ^ Tighten to 10 Nm (89 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Testing and Inspection Clutch Disc: Testing and Inspection Clutch Disc Check 1. Remove clutch assembly. 2. NOTE: Use emery cloth to remove minor imperfections in the clutch disc lining surface. Inspect clutch disc for: ^ oil or grease saturation. ^ worn or loose rivets at the hub. ^ broken springs. ^ wear or rust on splines. Install a new clutch disc if any of these conditions are present. 3. Use a slide caliper to measure the depth to the rivet heads. ^ Install a new clutch disc if not within specification. 4. Using a suitable dial indicator, measure the clutch disc runout. ^ Install a new clutch disc if not within specification. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Testing and Inspection > Page 4631 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Testing and Inspection > Page 4632 Clutch Disc: Service and Repair Clutch Disc and Pressure Plate Removal 1. Remove the transmission. 2. If the original components are to be installed, index-mark the clutch pressure plate and the flywheel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Testing and Inspection > Page 4633 3. Remove the clutch pressure plate bolts, clutch pressure plate and the clutch disc. Installation 1. Adjust the clutch pressure plate as follows: ^ Rotate the adjusting ring counterclockwise until the tension springs are compressed. ^ Hold the adjusting ring, then release the pressure on the clutch pressure plate fingers. 2. Using the special tool, position the clutch disc on the flywheel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Testing and Inspection > Page 4634 3. NOTE: If installing the original clutch pressure plate, use the index marks made during removal. Position the clutch pressure plate on the dowels, install the clutch pressure plate bolts and remove the special tool. ^ Tighten to 55 Nm (41 lb-ft). 4. Install the transmission. ^ Before securing the transmission to the engine, install the hydraulic line to the clutch slave cylinder. 5. Operate the vehicle to check clutch operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications > Capacity Specifications Clutch Fluid: Capacity Specifications Between MIN/MAX on brake fluid reservoir and to the line or step on clutch fluid reservoir. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications > Capacity Specifications > Page 4640 Clutch Fluid: Fluid Type Specifications BRAKE FLUID AND CLUTCH FLUID Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid Ford Part Number: .......................... .............................................................................................................................................................. ....... PM-1-C Ford Specification: ......................................................................................................... ......................................................................... WSS-M6C62-A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder and Reservoir Clutch Master Cylinder: Service and Repair Clutch Master Cylinder and Reservoir Clutch Master Cylinder and Reservoir Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder and Reservoir > Page 4645 Removal and Installation WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash the surface with water immediately. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Using the special tool, disconnect the hydraulic fluid tube from the clutch slave cylinder. ^ Clean the area around the quick disconnect coupling. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder and Reservoir > Page 4646 3. Remove the clutch pedal position (CPP) switch. 1 Disconnect the CPP switch electrical connector. 2 Disconnect the clutch master cylinder push rod from the pedal assembly. 3 Remove the CPP switch. ^ Lift the upper cover from the lock tabs and pull the cover upward. Rotate and remove the switch from the push rod. 4. Unclip the hydraulic fluid tube from the dash panel. 5. Remove the clutch reservoir from the dash panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder and Reservoir > Page 4647 6. Unlock and remove the clutch master cylinder. ^ Twist the clutch master cylinder counterclockwise 45 degrees to unlock it from the pedal support bracket. 7. Remove the clutch reservoir, clutch master cylinder and hydraulic fluid tube as an assembly. 8. To install, reverse the removal procedure. ^ Install a new clutch master cylinder push rod retainer. ^ If installing a new clutch master cylinder, install a new clutch master cylinder push rod. ^ Fill the reservoir with clean, specified brake fluid. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder and Reservoir > Page 4648 Clutch Master Cylinder: Service and Repair Clutch Slave Cylinder Clutch Slave Cylinder Clutch Slave Cylinder Removal and Installation WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash the surface with water immediately. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission. 3. Remove the 2 clutch slave cylinder bolts and the clutch slave cylinder. 4. Inspect the clutch slave cylinder for the following: ^ Damaged boot ^ Leaking brake fluid ^ Worn or damaged release bearing Rotate the release bearing while applying pressure. If the bearing rotation is rough, install a new clutch slave cylinder. Installation 1. Install the clutch slave cylinder and the 2 clutch slave cylinder bolts. ^ To install, tighten to 23 Nm (17 lb-ft). 2. Install the transmission. 3. Depress and release the clutch pedal several times to stabilize the clutch hydraulic system. 4. Remove the clutch reservoir cap and diaphragm. Check the fluid level. Fill the reservoir to or above the step mark. Install the cap and diaphragm. 5. Remove the bleeder screw cover and attach a vinyl hose to the bleeder hose. Place the other end of the vinyl hose into a clear container partially filled with brake fluid. 6. Have an assistant depress and release the clutch pedal 5 times, then hold the clutch pedal down. With the clutch pedal depressed, loosen the bleeder screw to let air escape the clutch system. Tighten the bleeder screw. Repeat this process until no air comes through the vinyl hose. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder and Reservoir > Page 4649 7. Tighten the bleeder screw and install the bleeder screw cover. 8. Slowly pump the clutch pedal several times to verify there is no fluid leakage. 9. Depress and release the clutch pedal 2 short cycles and 3 full-travel cycles. 10. Make sure the clutch reservoir is at the correct level. Refill as necessary. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Tools and Equipment Hydraulic Hose: Tools and Equipment Clutch Line Fork AST tool# 8008 Used for the R and R of the hydraulic clutch line from the internally mounted slave cylinder. This tool is applicable to the following Ford vehicles with manual transmissions: 1989 and later Ford Aerostar, Bronco II, Explorer, F150 and Ranger. - For R and R of Hydraulic Clutch Lines - Applicable to Ford Models with Manual Transmissions - Steel Construction - Black-Oxide Finish Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 4656 C257 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair Pilot Bearing: Service and Repair Pilot Bearing Removal 1. Using the special tool, remove the input shaft pilot bearing. Installation 1. NOTE: The input shaft pilot bearing can only be installed with the seal facing the transmission. The input shaft pilot bearing is pregreased and does not require additional lubrication. Using the special tool, install a new input shaft pilot bearing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Page 4660 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Pressure plate bolts ............................................................................................................................. ......................................................... 55 Nm (41 lb-ft) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 4664 Pressure Plate: Testing and Inspection Clutch Pressure Plate Check 1. Inspect clutch pressure plate for excessive wear or damage. ^ Install a new clutch pressure plate if necessary. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > Clutch Pressure Plate Locating Dowels Pressure Plate: Service and Repair Clutch Pressure Plate Locating Dowels Clutch Pressure Plate Locating Dowels Removal 1. NOTE: Take care not to damage the flywheel dowel holes or surface areas around the flywheel dowel during removal. Remove the flywheel dowels by using a drift pin where the flywheel dowel is installed in an open hole and locking pliers where the flywheel dowel is installed in a blind hole. Installation 1. NOTE: Care should be taken to drive the flywheel dowel squarely into place until fully seated. Be careful not to damage surrounding surface areas. Install all flywheel dowels by driving them into place using a brass or plastic mallet. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > Clutch Pressure Plate Locating Dowels > Page 4667 Pressure Plate: Service and Repair Clutch Disc and Pressure Plate Clutch Disc and Pressure Plate Removal 1. Remove the transmission. 2. If the original components are to be installed, index-mark the clutch pressure plate and the flywheel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > Clutch Pressure Plate Locating Dowels > Page 4668 3. Remove the clutch pressure plate bolts, clutch pressure plate and the clutch disc. Installation 1. Adjust the clutch pressure plate as follows: ^ Rotate the adjusting ring counterclockwise until the tension springs are compressed. ^ Hold the adjusting ring, then release the pressure on the clutch pressure plate fingers. 2. Using the special tool, position the clutch disc on the flywheel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > Clutch Pressure Plate Locating Dowels > Page 4669 3. NOTE: If installing the original clutch pressure plate, use the index marks made during removal. Position the clutch pressure plate on the dowels, install the clutch pressure plate bolts and remove the special tool. ^ Tighten to 55 Nm (41 lb-ft). 4. Install the transmission. ^ Before securing the transmission to the engine, install the hydraulic line to the clutch slave cylinder. 5. Operate the vehicle to check clutch operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Differential Cover: Service and Repair Ford 8.8-Inch Ring Gear Differential Housing Cover Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the differential housing cover. 1 Remove the 10 differential housing cover bolts and drain the lubricant from the axle housing. 2 Remove the differential housing cover. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4675 Installation 1. NOTE: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the silicone sealant. Cover the inside of the rear axle prior to cleaning the machined surface to prevent contamination. Clean the gasket mating surfaces. 2. Apply a new continuous bead of sealant to the differential housing cover. 3. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone sealant, or new sealant must be applied. If possible, allow one hour before filling the axle housing with axle lubricant to make sure the silicone sealant has correctly cured. Install the differential housing cover and the 10 differential housing cover bolts. ^ Tighten to 45 Nm (33 lb-ft). 4. NOTE: When filling a Traction-Lok axle with new lubricant, first fill the axle with 118 ml (4 oz) of friction modifier. NOTE: Service refill capacities are determined by filling the axle to the level shown. Remove the filler plug, fill the axle with 2.6L (5.5 pt) of axle lubricant and install the filler plug. ^ Tighten to 52 Nm (38 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4676 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4677 Differential Cover: Service and Repair Ford 9.75-Inch Ring Gear Differential Housing Cover Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the differential housing cover. 1 Remove the 12 differential housing cover bolts, and drain the lubricant from the axle housing. 2 Remove the differential housing cover. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4678 Installation 1. NOTE: Make sure the machined surfaces on both the axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the axle must be covered when cleaning the machined surface to prevent contamination. Clean the gasket mating surface of the axle and the differential housing cover. 2. Apply a new, continuous bead of sealant to the differential housing cover. 3. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has correctly cured. Install the differential housing cover and the 12 differential housing cover bolts. ^ Tighten to 45 Nm (33 lb-ft). 4. Remove the fill plug. 5. NOTE: For Traction-Lok axles, first fill the axle with 118 ml (4 oz) of friction modifier. NOTE: Service refill capacities are determined by filling the axle with the specified lubricant to the specified level below the bottom of the filler hole. Fill the axle to the level shown with axle lubricant and install the filler plug. ^ Tighten to 30 Nm (22 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4679 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4680 Differential Cover: Service and Repair Ford 10.25-Inch Ring Gear Differential Housing Cover Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the differential housing cover. 1 Remove the 12 differential housing cover bolts, and drain the lubricant from the axle housing. 2 Remove the differential housing cover. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4681 Installation 1. NOTE: Make sure the machined surfaces on both the axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the axle must be covered when cleaning the machined surface to prevent contamination. Clean the gasket mating surface of the axle and the differential housing cover. 2. Apply a new, continuous bead of sealant to the differential housing cover. 3. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has correctly cured. Install the differential housing cover and the 12 differential housing cover bolts. ^ Tighten to 45 Nm (33 lb-ft). 4. NOTE: For Traction-Lok axles, first fill the axle with 118 ml (4 oz) of friction modifier. NOTE: Service refill capacities are determined by filling the axle with the specified lubricant to the specified level below the bottom of the filler hole. Remove the fill plug, fill the axle to the level shown with axle lubricant and install the fill plug. ^ Tighten to 30 Nm (22 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4682 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity FRONT AXLE 4x4 vehicles ................................................................................................................. .................................................................................. 3.5 pints (1.8L) REAR AXLE 8.8/9.75 inch axle ........................................................................................................... ............................................................................... 5.5 pints (2.6L) 10.25 inch axle ........................... .............................................................................................................................................................. ..... 6.9 pints (3.3L) NOTE: Service refill capacity is determined by filling the axle to 1/4-9/16 inch (6-14 mm) below the bottom of the filler hole with the vehicle on a level surface. Add 4 oz. (118 ml) of Additive Friction Modifier XL3 or equivalent meeting Ford specification EST-M2C118A, for complete fill of 8.8 inch and 9.75 inch Traction-Lok axles. NOTE: Service refill capacity is determined by filling the axle to the bottom of the filler hole with the vehicle on a level surface. For 10.25 inch Traction-Lok axles, use 6.5 pints (3.1L) of Motorcraft SAE 75W-140 Synthetic Rear Axle Lubricant and 8 oz. (236 ml) of Additive Friction Modifier XL3 or equivalent meeting Ford Specification EST-M2C118-A. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 4687 Fluid - Differential: Fluid Type Specifications REAR 8.8 / 9.75 / 10.25 AXLE Rear axle.......................................................................................................................................Motorcraft SAE 75W-140 Synthetic Rear Axle Lubricant Ford Part Number......................................................... ...........................................................................XY-75W140-QL(US) / CXY-75W140-1L(Canada) Ford Specification................................................................................................................................. ........................................................WSL-M2C192-A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Pinion Flange: Service and Repair Ford 8.8-Inch Ring Gear Drive Pinion Flange and Drive Pinion Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4692 Removal CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the brake disc. 3. Remove the driveshaft. 4. Using a Nm (lb-in) torque wrench on the pinion nut, record the torque required to maintain rotation of the pinion gear through several revolutions. 5. Using the special tool to hold the pinion flange, remove and discard the pinion nut. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4693 6. Index-mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation. 7. Using the special tool, remove the pinion flange. 8. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the drive pinion seal is removed. Installation 1. Lubricate the new drive pinion seal with grease. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4694 2. NOTE: If the new drive pinion seal becomes misaligned during installation, remove the drive pinion seal and install a new drive pinion seal. Using the special tool, install a new drive pinion seal. 3. Lubricate the pinion flange splines with axle lubricant. 4. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft. 5. Using the special tools, install the pinion flange. 6. CAUTION: Install a new pinion nut with the same color as the original if not replacing the collapsible spacer. If a new collapsible spacer is installed, install the nut in the kit or damage to the component may occur. Position the new pinion nut. 8.8-In Drive Pinion Nut Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4695 7. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce drive pinion bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion collapsible spacer and pinion nut must be installed or damage to the component may occur. CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur. NOTE: Remove the special tool while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench. Using the special tool to hold the pinion flange, tighten the pinion nut. ^ Rotate the drive pinion occasionally to make sure the drive pinion bearings are seating correctly. ^ Install a Nm (lb-in) torque wrench on the pinion nut. ^ Rotating the drive pinion through several revolutions, take frequent drive pinion bearing preload readings until the original recorded drive pinion bearing preload reading is obtained. ^ If the original recorded drive pinion bearing preload is lower than specifications, tighten to the appropriate specifications for used drive pinion bearings. If the drive pinion bearing preload is higher than specification, tighten the pinion nut to the original reading as recorded. 8. Install the driveshaft. 9. Install the brake disc. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4696 Pinion Flange: Service and Repair Ford 9.75-Inch Ring Gear Drive Pinion Flange and Drive Pinion Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4697 Removal CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the brake disc. 3. Index-mark the driveshaft flange and pinion flange for correct alignment during installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4698 4. Remove the 4 driveshaft flange bolts. 5. NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft centering socket yoke from the pinion flange. Pry only in the area shown with a suitable tool to disconnect the driveshaft centering socket yoke from the pinion flange. Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the pinion flange. ^ Using mechanic's wire, position the driveshaft aside. 6. Using a Nm (lb-in) torque wrench on the pinion nut, record the torque required to maintain rotation of the pinion gear through several revolutions. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4699 7. Using the special tool to hold the pinion flange, remove and discard the pinion nut. 8. Index-mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation. 9. Using the special tool, remove the pinion flange. 10. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the drive pinion seal is removed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4700 Installation 1. Lubricate the new drive pinion seal with grease. 2. Using the special tool, install a new drive pinion seal. 3. Lubricate the pinion flange splines with axle lubricant. 4. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft. 5. Using the special tool, install the pinion flange. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4701 6. CAUTION: Install a new pinion nut with the same color as the original if not replacing the collapsible spacer. If a new collapsible spacer is installed, install the nut in the kit, as indicated in the chart below, or damage to the component may occur. Position the new pinion nut. 9.75 In. Drive Pinion Nut 7. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce drive pinion bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion collapsible spacer and pinion nut must be installed or damage to the component may occur. NOTE: Remove the special tool while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench. Using the special tool to hold the pinion flange, tighten the pinion nut. ^ Rotate the drive pinion occasionally to make sure the drive pinion bearings are seating correctly. ^ Install a Nm (lb-in) torque wrench on the pinion nut. ^ Rotating the drive pinion through several revolutions, take frequent drive pinion bearing preload readings until the original recorded drive pinion bearing preload reading is obtained. ^ If the original recorded drive pinion bearing preload is lower than specification, tighten to the appropriate specification for used drive pinion bearings. If the drive pinion bearing preload is higher than specification, tighten the pinion nut to the original reading as recorded. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4702 8. Position the driveshaft and align the index mark on the pinion flange. 9. NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the driveshaft centering socket yoke seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross pattern. Install the 4 driveshaft flange bolts. ^ Tighten to 103 Nm (76 lb-ft). 10. Install the rear brake disc. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4703 Pinion Flange: Service and Repair Ford 10.25-Inch Ring Gear Drive Pinion Flange and Drive Pinion Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4704 Removal CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the brake disc. 3. Index-mark the driveshaft flange and pinion flange for correct alignment during installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4705 4. Remove the 4 driveshaft flange bolts. 5. NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft centering socket yoke from the pinion flange. Pry only in the area shown with a suitable tool to disconnect the driveshaft centering socket yoke from the pinion flange. Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the pinion flange. ^ Using mechanic's wire, position the driveshaft aside. 6. Using a Nm (lb-in) torque wrench on the pinion nut, record the torque required to maintain rotation of the pinion gear through several revolutions. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4706 7. Using the special tool to hold the pinion flange, remove and discard the pinion nut. 8. Index-mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation. 9. Using the special tool, remove the pinion flange. 10. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the drive pinion seal is removed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4707 Installation 1. Lubricate the new drive pinion seal with grease. 2. Using the special tool, install a new drive pinion seal. 3. Lubricate the pinion flange splines with axle lubricant. 4. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft. 5. Using the special tool, install the pinion flange. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4708 6. CAUTION: Install a new pinion nut with the same color as the original if not replacing the collapsible spacer. If a new collapsible spacer is installed, install the nut in the kit or damage to the component may occur. Position the new pinion nut. 10.25-In Drive Pinion Nut 7. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce drive pinion bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion collapsible spacer and pinion nut must be installed or damage to the component may occur. CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur. NOTE: Remove the special tool while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench. Using the special tool to hold the pinion flange, tighten the pinion nut. ^ Rotate the drive pinion occasionally to make sure the drive pinion bearings are seating correctly. ^ Install a Nm (lb-in) torque wrench on the pinion nut. ^ Rotating the drive pinion through several revolutions, take frequent drive pinion bearing preload readings until the original recorded drive pinion bearing preload reading is obtained. ^ If the original recorded drive pinion bearing preload is lower than specification, tighten to the appropriate specification for used drive pinion bearings. If the drive pinion bearing preload is higher than specification, tighten the pinion nut to the original reading as recorded. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4709 8. Position the driveshaft and align the index mark on the pinion flange. 9. NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the driveshaft centering socket yoke seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross pattern. Install the 4 driveshaft flange bolts. ^ Tighten to 103 Nm (76 lb-ft). 10. Install the brake disc. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4710 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear Seals and Gaskets: Service and Repair Ford 8.8-Inch Ring Gear Drive Pinion Flange and Drive Pinion Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4715 Removal CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the brake disc. 3. Remove the driveshaft. 4. Using a Nm (lb-in) torque wrench on the pinion nut, record the torque required to maintain rotation of the pinion gear through several revolutions. 5. Using the special tool to hold the pinion flange, remove and discard the pinion nut. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4716 6. Index-mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation. 7. Using the special tool, remove the pinion flange. 8. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the drive pinion seal is removed. Installation 1. Lubricate the new drive pinion seal with grease. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4717 2. NOTE: If the new drive pinion seal becomes misaligned during installation, remove the drive pinion seal and install a new drive pinion seal. Using the special tool, install a new drive pinion seal. 3. Lubricate the pinion flange splines with axle lubricant. 4. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft. 5. Using the special tools, install the pinion flange. 6. CAUTION: Install a new pinion nut with the same color as the original if not replacing the collapsible spacer. If a new collapsible spacer is installed, install the nut in the kit or damage to the component may occur. Position the new pinion nut. 8.8-In Drive Pinion Nut Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4718 7. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce drive pinion bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion collapsible spacer and pinion nut must be installed or damage to the component may occur. CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur. NOTE: Remove the special tool while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench. Using the special tool to hold the pinion flange, tighten the pinion nut. ^ Rotate the drive pinion occasionally to make sure the drive pinion bearings are seating correctly. ^ Install a Nm (lb-in) torque wrench on the pinion nut. ^ Rotating the drive pinion through several revolutions, take frequent drive pinion bearing preload readings until the original recorded drive pinion bearing preload reading is obtained. ^ If the original recorded drive pinion bearing preload is lower than specifications, tighten to the appropriate specifications for used drive pinion bearings. If the drive pinion bearing preload is higher than specification, tighten the pinion nut to the original reading as recorded. 8. Install the driveshaft. 9. Install the brake disc. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4719 Seals and Gaskets: Service and Repair Ford 9.75-Inch Ring Gear Drive Pinion Flange and Drive Pinion Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4720 Removal CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the brake disc. 3. Index-mark the driveshaft flange and pinion flange for correct alignment during installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4721 4. Remove the 4 driveshaft flange bolts. 5. NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft centering socket yoke from the pinion flange. Pry only in the area shown with a suitable tool to disconnect the driveshaft centering socket yoke from the pinion flange. Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the pinion flange. ^ Using mechanic's wire, position the driveshaft aside. 6. Using a Nm (lb-in) torque wrench on the pinion nut, record the torque required to maintain rotation of the pinion gear through several revolutions. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4722 7. Using the special tool to hold the pinion flange, remove and discard the pinion nut. 8. Index-mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation. 9. Using the special tool, remove the pinion flange. 10. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the drive pinion seal is removed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4723 Installation 1. Lubricate the new drive pinion seal with grease. 2. Using the special tool, install a new drive pinion seal. 3. Lubricate the pinion flange splines with axle lubricant. 4. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft. 5. Using the special tool, install the pinion flange. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4724 6. CAUTION: Install a new pinion nut with the same color as the original if not replacing the collapsible spacer. If a new collapsible spacer is installed, install the nut in the kit, as indicated in the chart below, or damage to the component may occur. Position the new pinion nut. 9.75 In. Drive Pinion Nut 7. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce drive pinion bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion collapsible spacer and pinion nut must be installed or damage to the component may occur. NOTE: Remove the special tool while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench. Using the special tool to hold the pinion flange, tighten the pinion nut. ^ Rotate the drive pinion occasionally to make sure the drive pinion bearings are seating correctly. ^ Install a Nm (lb-in) torque wrench on the pinion nut. ^ Rotating the drive pinion through several revolutions, take frequent drive pinion bearing preload readings until the original recorded drive pinion bearing preload reading is obtained. ^ If the original recorded drive pinion bearing preload is lower than specification, tighten to the appropriate specification for used drive pinion bearings. If the drive pinion bearing preload is higher than specification, tighten the pinion nut to the original reading as recorded. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4725 8. Position the driveshaft and align the index mark on the pinion flange. 9. NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the driveshaft centering socket yoke seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross pattern. Install the 4 driveshaft flange bolts. ^ Tighten to 103 Nm (76 lb-ft). 10. Install the rear brake disc. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4726 Seals and Gaskets: Service and Repair Ford 10.25-Inch Ring Gear Drive Pinion Flange and Drive Pinion Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4727 Removal CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the brake disc. 3. Index-mark the driveshaft flange and pinion flange for correct alignment during installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4728 4. Remove the 4 driveshaft flange bolts. 5. NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft centering socket yoke from the pinion flange. Pry only in the area shown with a suitable tool to disconnect the driveshaft centering socket yoke from the pinion flange. Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the pinion flange. ^ Using mechanic's wire, position the driveshaft aside. 6. Using a Nm (lb-in) torque wrench on the pinion nut, record the torque required to maintain rotation of the pinion gear through several revolutions. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4729 7. Using the special tool to hold the pinion flange, remove and discard the pinion nut. 8. Index-mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation. 9. Using the special tool, remove the pinion flange. 10. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the drive pinion seal is removed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4730 Installation 1. Lubricate the new drive pinion seal with grease. 2. Using the special tool, install a new drive pinion seal. 3. Lubricate the pinion flange splines with axle lubricant. 4. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft. 5. Using the special tool, install the pinion flange. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4731 6. CAUTION: Install a new pinion nut with the same color as the original if not replacing the collapsible spacer. If a new collapsible spacer is installed, install the nut in the kit or damage to the component may occur. Position the new pinion nut. 10.25-In Drive Pinion Nut 7. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce drive pinion bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion collapsible spacer and pinion nut must be installed or damage to the component may occur. CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur. NOTE: Remove the special tool while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench. Using the special tool to hold the pinion flange, tighten the pinion nut. ^ Rotate the drive pinion occasionally to make sure the drive pinion bearings are seating correctly. ^ Install a Nm (lb-in) torque wrench on the pinion nut. ^ Rotating the drive pinion through several revolutions, take frequent drive pinion bearing preload readings until the original recorded drive pinion bearing preload reading is obtained. ^ If the original recorded drive pinion bearing preload is lower than specification, tighten to the appropriate specification for used drive pinion bearings. If the drive pinion bearing preload is higher than specification, tighten the pinion nut to the original reading as recorded. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4732 8. Position the driveshaft and align the index mark on the pinion flange. 9. NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the driveshaft centering socket yoke seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross pattern. Install the 4 driveshaft flange bolts. ^ Tighten to 103 Nm (76 lb-ft). 10. Install the brake disc. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4733 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Testing and Inspection Axle Shaft Assembly: Testing and Inspection Inspection and Verification 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical damage. Visual Inspection Chart 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the cause is not visually evident, verify the symptom and GO to the Symptom Chart - Driveline or GO to Symptom Chart - Noise, Vibration and Harshness (NVH). See: Differential Assembly/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptom Chart - Driveline See: Differential Assembly/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptom Chart - Noise, Vibration and Harshness (NVH) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Axle Shaft Assembly: Service and Repair Ford 8.8-Inch Ring Gear Axle Shaft Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the rear wheel and tire. 3. Remove the rear brake disc. 4. Remove the differential housing cover and drain the lubricant. 5. Remove the differential pinion shaft. 1 Remove and discard the 1 bolt. 2 Remove the differential pinion shaft. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4740 6. NOTE: Do not damage the rubber O-ring in the U-washer groove. Remove the U-washer. 1 Push the axle shaft inboard. 2 Remove the U-washer. 7. NOTE: Do not damage the wheel bearing oil seal. Remove the axle shaft. Installation 1. Lubricate the lip of the wheel bearing oil seal with grease. 2. NOTE: Do not damage the wheel bearing oil seal. Install the axle shaft. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4741 3. NOTE: Do not damage the rubber O-ring in the U-washer groove. Install the U-washer. 1 Position the U-washer on the button end of the axle shaft. 2 Pull the axle shaft outward. 4. NOTE: If a new bolt is unavailable, coat the bolt threads with threadlock prior to installation. Install the differential pinion shaft. ^ Align the bolt hole in the differential pinion shaft with the bolt hole in the case. ^ Install the new pinion shaft lock bolt. ^ Tighten to 30 Nm (22 lb-ft). 5. Install the rear brake disc. 6. Install the differential housing cover and fill the differential housing with the specified lubricant. 7. Install the rear wheel and tire. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4742 Axle Shaft Assembly: Service and Repair Ford 9.75-Inch Ring Gear Axle Shaft Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 12 differential housing cover bolts and remove the differential cover. 3. Remove the rear brake disc. 4. Remove the differential pinion shaft. 1 Remove and discard the differential pinion shaft lock bolt. 2 Remove the differential pinion shaft. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4743 5. Remove the U-washer. 1 Push in on the axle shaft. 2 Remove the U-washer. 6. Remove the axle shaft. Installation 1. Lubricate the lip of the axle shaft oil seal with grease. 2. Install the axle shaft. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4744 3. NOTE: Do not damage the rubber O-rings in the U-washer grooves. Install the U-washer. 1 Position the U-washer on the button end of the axle shaft. 2 Pull the axle shaft outward. 4. NOTE: If a new differential pinion shaft lock bolt is unavailable coat the threads of the original differential pinion shaft lock bolt with threadlock prior to installation. Install the differential pinion shaft. 1 Align the hole in the differential pinion shaft with the differential case lock bolt hole. 2 Install a new differential pinion shaft lock bolt. ^ Tighten to 30 Nm (22 lb-ft). 5. Install the rear brake disc. 6. NOTE: Make sure the machined surfaces on both the axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the axle must be covered when cleaning the machined surface to prevent contamination. Clean the gasket mating surface of the axle and the differential housing cover. 7. Apply a new, continuous bead of sealant to the differential housing cover. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4745 8. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to ensure the silicone sealant has correctly cured. Install the differential housing cover and the differential housing cover bolts. ^ Tighten to 45 Nm (33 lb-ft). 9. NOTE: For Traction-Lok axles, first fill the axle with 118 ml (4 oz) of friction modifier. NOTE: Service refill capacities are determined by filling the axle with the specified lubricant to the specified level below the bottom of the filler hole. Remove the fill plug, fill the axle to the level shown with axle lubricant and install the filler plug. ^ Tighten to 30 Nm (22 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4746 Axle Shaft Assembly: Service and Repair Ford 10.25-Inch Ring Gear Axle Shaft Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the differential housing cover. 3. Remove the rear brake disc. 4. Remove the differential pinion shaft. 1 Remove and discard the differential pinion shaft lock bolt. 2 Remove the differential pinion shaft. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4747 5. NOTE: Do not damage the rubber O-rings in the axle shaft grooves. Remove the U-washer. 1 Push in on the axle shaft. 2 Remove the U-washer. 6. CAUTION: Do not damage the axle shaft oil seal. Remove the axle shaft. Installation 1. Lubricate the lip of the axle shaft oil seal with grease. 2. Install the axle shaft. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4748 3. Install the U-washer. 1 Position the U-washer on the button end of the axle shaft. 2 Pull the axle shaft outward. 4. NOTE: If a new differential pinion shaft lock bolt is unavailable, coat the threads of the original differential pinion shaft lock bolt with threadlock prior to installation. Install the differential pinion shaft. 1 Align the hole in the differential pinion shaft with the differential case lock bolt hole. 2 Install a new differential pinion shaft lock bolt. ^ Tighten to 30 Nm (22 lb-ft). 5. Install the rear brake disc. 6. Install the differential housing cover. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Ford 8.8-Inch Ring Gear Seals and Gaskets: Service and Repair Ford 8.8-Inch Ring Gear Rear Wheel Bearing and Axle Shaft Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4753 Removal 1. Remove the axle shaft. 2. NOTE: If the axle shaft oil seal is leaking, the axle housing vent may be plugged with foreign material. NOTE: Use care to avoid damaging the axle shaft oil seal bore. Using a suitable seal remover, remove and discard the axle shaft oil seal. 3. Inspect the rear wheel bearing and axle shaft for wear or damage. 4. If necessary, using the special tools, remove the rear wheel bearing. Installation 1. If removed, lubricate the new rear wheel bearing with axle lubricant. 2. If removed, use the special tools to install the rear wheel bearing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4754 3. Lubricate the lip of the new axle shaft oil seal with grease. 4. Using the special tools, install the new axle shaft oil seal. 5. Install the axle shaft. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4755 Seals and Gaskets: Service and Repair Ford 9.75-Inch Ring Gear Rear Wheel Bearing and Axle Shaft Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4756 Removal 1. Remove the axle shaft. 2. NOTE: If only a new axle shaft oil seal needs to be installed, use care to avoid damaging the axle shaft oil seal bore. Using a suitable seal remover, remove and discard the axle shaft oil seal. 3. Inspect the rear wheel bearing and axle shaft for wear or damage. 4. Using the special tools, remove the rear wheel bearing. Installation 1. Lubricate the new rear wheel bearing with axle lubricant. 2. Using the special tools, install the rear wheel bearing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4757 3. Lubricate the lip of the new axle shaft oil seal with grease. 4. Using the special tools, install the new axle shaft oil seal. 5. Install the axle shaft. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4758 Seals and Gaskets: Service and Repair Ford 10.25-Inch Ring Gear Rear Wheel Bearing and Axle Shaft Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4759 Removal 1. Remove the axle shaft. 2. NOTE: If only a new axle shaft oil seal needs to be installed, use care to avoid damaging the axle shaft oil seal bore. Using a suitable seal remover, remove and discard the axle shaft oil seal. 3. Inspect the rear wheel bearing and axle shaft for wear or damage. 4. Using the special tools, remove the rear wheel bearing. Installation 1. Lubricate the new rear wheel bearing with axle lubricant. 2. Using the special tools, install the rear wheel bearing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 4760 3. Lubricate the lip of the new axle shaft oil seal with grease. 4. Using the special tools, install the new axle shaft oil seal. 5. Install the axle shaft. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications SPINDLE BEARING LUBRICANT Premium Long-Life Grease Ford Part Number ..................................................................................................................................... XG-1-C or XG-1-K (US); CXG-1-C (Canada) Ford Specification .......................................................................... ............................................................................................................ ESA-M1C75-B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 Wheel Bearing and Wheel Hub Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to make sure correct retention of these parts. 1. Remove the wheel and tire. 2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the 2 bolts and position the caliper and anchor plate assembly aside. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 200 Nm (148 lb-ft). 3. Remove the cotter pin and wheel hub nut retainer. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4766 ^ Discard the cotter pin. 4. Remove and discard the wheel hub nut. ^ To install, tighten to 400 Nm (296 lb-ft). 5. Remove the brake disc/wheel bearing and wheel hub assembly. 6. CAUTION: Do not apply lubricant to the threaded end of the wheel spindle or incorrect clamp load may occur. NOTE: Clean the wheel spindle (including the threaded end) of any dirt or grease using the specified solvent before installing the brake disc. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4767 Wheel Bearing: Service and Repair Rear Ford 8.8-Inch Ring Gear Rear Wheel Bearing and Axle Shaft Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4768 Removal 1. Remove the axle shaft. 2. NOTE: If the axle shaft oil seal is leaking, the axle housing vent may be plugged with foreign material. NOTE: Use care to avoid damaging the axle shaft oil seal bore. Using a suitable seal remover, remove and discard the axle shaft oil seal. 3. Inspect the rear wheel bearing and axle shaft for wear or damage. 4. If necessary, using the special tools, remove the rear wheel bearing. Installation 1. If removed, lubricate the new rear wheel bearing with axle lubricant. 2. If removed, use the special tools to install the rear wheel bearing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4769 3. Lubricate the lip of the new axle shaft oil seal with grease. 4. Using the special tools, install the new axle shaft oil seal. 5. Install the axle shaft. Ford 9.75-Inch Ring Gear Rear Wheel Bearing and Axle Shaft Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4770 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4771 Removal 1. Remove the axle shaft. 2. NOTE: If only a new axle shaft oil seal needs to be installed, use care to avoid damaging the axle shaft oil seal bore. Using a suitable seal remover, remove and discard the axle shaft oil seal. 3. Inspect the rear wheel bearing and axle shaft for wear or damage. 4. Using the special tools, remove the rear wheel bearing. Installation 1. Lubricate the new rear wheel bearing with axle lubricant. 2. Using the special tools, install the rear wheel bearing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4772 3. Lubricate the lip of the new axle shaft oil seal with grease. 4. Using the special tools, install the new axle shaft oil seal. 5. Install the axle shaft. Ford 10.25-Inch Ring Gear Rear Wheel Bearing and Axle Shaft Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4773 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4774 Removal 1. Remove the axle shaft. 2. NOTE: If only a new axle shaft oil seal needs to be installed, use care to avoid damaging the axle shaft oil seal bore. Using a suitable seal remover, remove and discard the axle shaft oil seal. 3. Inspect the rear wheel bearing and axle shaft for wear or damage. 4. Using the special tools, remove the rear wheel bearing. Installation 1. Lubricate the new rear wheel bearing with axle lubricant. 2. Using the special tools, install the rear wheel bearing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4775 3. Lubricate the lip of the new axle shaft oil seal with grease. 4. Using the special tools, install the new axle shaft oil seal. 5. Install the axle shaft. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations View 151-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 4780 C1291 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Technical Service Bulletins > Customer Interest for Center Support: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration Center Support: Customer Interest Drivetrain - Highway Speed Vibration TSB 07-10-9 05/28/07 VIBRATION FROM THE DRIVELINE AT HIGHWAY SPEEDS FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 06-12-3 to update the vehicle model years. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT vehicles (excluding F-150 Heritage) may exhibit a vibration, felt in the floorpan and/or steering wheel when driven at highway speeds ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Technical Service Bulletins > Customer Interest for Center Support: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4790 Refer to the Diagnostic Overview (Figure 1). Based on the customer's description of the concern, find the appropriate Operating Condition, Probable Cause and Repair Action. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Technical Service Bulletins > Customer Interest for Center Support: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4791 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Technical Service Bulletins > Customer Interest for Center Support: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4792 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Technical Service Bulletins > Customer Interest for Center Support: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4793 NOTE IT IS CRITICAL TO IDENTIFY SPECIFIC VEHICLE SPEEDS AND OPERATING CONDITIONS WHEN THE VIBRATION OR NIBBLE IS OCCURRING, TO PROPERLY DIAGNOSE AND REPAIR THE ISSUE. TIRE AND DRIVELINE VIBRATION CAN FEEL SIMILAR. USE OF AN ELECTRONIC VIBRATION ANALYZER (EVA) OR VETRONIX VIBRATION ANALYZER IS RECOMMENDED TO CORRECTLY IDENTIFY VIBRATION SOURCES (ORDERS) AND FREQUENCY (HZ). Parts Block OTHER APPLICABLE ARTICLES: 07-10-08, 06-19-16 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT071009 Claim Labor As Actual Actual Time Or Use SLIS Time Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 4602 42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Technical Service Bulletins > Customer Interest for Center Support: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4794 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Support: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration Center Support: All Technical Service Bulletins Drivetrain - Highway Speed Vibration TSB 07-10-9 05/28/07 VIBRATION FROM THE DRIVELINE AT HIGHWAY SPEEDS FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 06-12-3 to update the vehicle model years. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT vehicles (excluding F-150 Heritage) may exhibit a vibration, felt in the floorpan and/or steering wheel when driven at highway speeds ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Support: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4800 Refer to the Diagnostic Overview (Figure 1). Based on the customer's description of the concern, find the appropriate Operating Condition, Probable Cause and Repair Action. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Support: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4801 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Support: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4802 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Support: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4803 NOTE IT IS CRITICAL TO IDENTIFY SPECIFIC VEHICLE SPEEDS AND OPERATING CONDITIONS WHEN THE VIBRATION OR NIBBLE IS OCCURRING, TO PROPERLY DIAGNOSE AND REPAIR THE ISSUE. TIRE AND DRIVELINE VIBRATION CAN FEEL SIMILAR. USE OF AN ELECTRONIC VIBRATION ANALYZER (EVA) OR VETRONIX VIBRATION ANALYZER IS RECOMMENDED TO CORRECTLY IDENTIFY VIBRATION SOURCES (ORDERS) AND FREQUENCY (HZ). Parts Block OTHER APPLICABLE ARTICLES: 07-10-08, 06-19-16 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT071009 Claim Labor As Actual Actual Time Or Use SLIS Time Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 4602 42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Support: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4804 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration Drive/Propeller Shaft: Customer Interest Drivetrain - Highway Speed Vibration TSB 07-10-9 05/28/07 VIBRATION FROM THE DRIVELINE AT HIGHWAY SPEEDS FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 06-12-3 to update the vehicle model years. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT vehicles (excluding F-150 Heritage) may exhibit a vibration, felt in the floorpan and/or steering wheel when driven at highway speeds ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4813 Refer to the Diagnostic Overview (Figure 1). Based on the customer's description of the concern, find the appropriate Operating Condition, Probable Cause and Repair Action. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4814 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4815 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4816 NOTE IT IS CRITICAL TO IDENTIFY SPECIFIC VEHICLE SPEEDS AND OPERATING CONDITIONS WHEN THE VIBRATION OR NIBBLE IS OCCURRING, TO PROPERLY DIAGNOSE AND REPAIR THE ISSUE. TIRE AND DRIVELINE VIBRATION CAN FEEL SIMILAR. USE OF AN ELECTRONIC VIBRATION ANALYZER (EVA) OR VETRONIX VIBRATION ANALYZER IS RECOMMENDED TO CORRECTLY IDENTIFY VIBRATION SOURCES (ORDERS) AND FREQUENCY (HZ). Parts Block OTHER APPLICABLE ARTICLES: 07-10-08, 06-19-16 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT071009 Claim Labor As Actual Actual Time Or Use SLIS Time Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 4602 42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4817 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration Drive/Propeller Shaft: All Technical Service Bulletins Drivetrain - Highway Speed Vibration TSB 07-10-9 05/28/07 VIBRATION FROM THE DRIVELINE AT HIGHWAY SPEEDS FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 06-12-3 to update the vehicle model years. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT vehicles (excluding F-150 Heritage) may exhibit a vibration, felt in the floorpan and/or steering wheel when driven at highway speeds ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4823 Refer to the Diagnostic Overview (Figure 1). Based on the customer's description of the concern, find the appropriate Operating Condition, Probable Cause and Repair Action. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4824 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4825 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4826 NOTE IT IS CRITICAL TO IDENTIFY SPECIFIC VEHICLE SPEEDS AND OPERATING CONDITIONS WHEN THE VIBRATION OR NIBBLE IS OCCURRING, TO PROPERLY DIAGNOSE AND REPAIR THE ISSUE. TIRE AND DRIVELINE VIBRATION CAN FEEL SIMILAR. USE OF AN ELECTRONIC VIBRATION ANALYZER (EVA) OR VETRONIX VIBRATION ANALYZER IS RECOMMENDED TO CORRECTLY IDENTIFY VIBRATION SOURCES (ORDERS) AND FREQUENCY (HZ). Parts Block OTHER APPLICABLE ARTICLES: 07-10-08, 06-19-16 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT071009 Claim Labor As Actual Actual Time Or Use SLIS Time Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 4602 42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4827 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Rear, One-Piece Drive/Propeller Shaft: Service and Repair Driveshaft - Rear, One-Piece Driveshaft - Rear, One-Piece Removal and Installation NOTE: For automatic transmissions, when installing a new driveshaft, match the yellow dots on the driveshaft to the yellow dots on the pinion flange and the output shaft to maintain balance during installation. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Index-mark the driveshaft flange to the pinion flange to maintain alignment during installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Rear, One-Piece > Page 4830 3. Index-mark the driveshaft to the extension housing to maintain alignment during installation. 4. Remove and discard the 4 driveshaft flange bolts. ^ To install, tighten the 4 new bolts to 103 Nm (76 lb-ft). 5. CAUTION: The driveshaft flange fits tightly on the flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the flange pilot. Pry only in the area shown with a suitable tool to disconnect the driveshaft flange from the flange pilot or damage to the driveshaft flange can occur. Using a suitable tool as shown, disconnect the driveshaft flange from the flange pilot and remove the driveshaft. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Rear, One-Piece > Page 4831 6. Plug the extension housing to prevent fluid loss. 7. CAUTION: The driveshaft flange fits tightly on the pinion flange pilots. To make sure that the driveshaft flanges seat squarely on the pinion flange pilots, tighten the driveshaft flange bolts evenly in a cross pattern or damage to the flanges can occur. NOTE: If new bolts are not available, coat the threads of the original driveshaft flange bolts with threadlock and sealer. NOTE: Align the index marks made during removal. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Rear, One-Piece > Page 4832 Drive/Propeller Shaft: Service and Repair Driveshaft - Rear, Two-Piece Driveshaft - Rear, Two-Piece Removal and Installation NOTE: For automatic transmissions, when installing a new driveshaft, match the yellow dots on the driveshaft to the yellow dots on the pinion flange and the output shaft to maintain balance during installation. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Index-mark the driveshaft flange to the pinion flange to maintain alignment during installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Rear, One-Piece > Page 4833 3. Index-mark the driveshaft to the extension housing to maintain alignment during installation. 4. Remove and discard the 4 driveshaft flange bolts. ^ To install, tighten the 4 new bolts to 103 Nm (76 lb-ft). 5. CAUTION: The driveshaft flange fits tightly on the flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the flange pilot. Pry only in the area shown with a suitable tool, to disconnect the driveshaft flange from the flange pilot or damage to the driveshaft flange can occur. Using a suitable tool as shown, disconnect the driveshaft flange from the flange pilot. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Rear, One-Piece > Page 4834 6. Remove the driveshaft center bearing bolts and remove the driveshaft in the following sequence. 1 Remove the 2 driveshaft center bearing bolts. 2 Lower the driveshaft and slide the driveshaft slip yoke rearward off of the output shaft. ^ To install, tighten to 48 Nm (35 lb-ft). 7. Plug the extension housing to prevent fluid loss. 8. CAUTION: The driveshaft flange fits tightly on the pinion flange pilots. To make sure that the driveshaft flanges seat squarely on the pinion flange pilots, tighten the driveshaft flange bolts evenly in a cross pattern or damage to the driveshaft flange can occur. NOTE: If new bolts are not available, coat the threads of the original driveshaft flange bolts with threadlock and sealer. NOTE: Align the index marks made during removal. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Rear, One-Piece > Page 4835 Drive/Propeller Shaft: Service and Repair Driveshaft Slip Yoke Boot Driveshaft Slip Yoke Boot Removal 1. Remove the driveshaft. 2. CAUTION: Do not, under any circumstance, clamp the driveshaft in the jaws of a vise or similar holding fixture. Denting or localizing fracture can result, causing driveshaft failure during vehicle operation. Place the driveshaft on a suitable workbench. Do not damage the tubes. 3. Remove the driveshaft slip yoke from the driveshaft in the following sequence. 1 Cut and discard the driveshaft slip-yoke boot clamps. 2 Remove the driveshaft slip yoke from the driveshaft. 4. Remove the slip-yoke boot from the driveshaft. ^ Inspect the boot for damage. Discard the boot as necessary. 5. Inspect the lubricant on the driveshaft splines and in the driveshaft slip yoke for contamination. If contaminated, inspect the driveshaft splines and Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Rear, One-Piece > Page 4836 the driveshaft slip yoke for wear. Install new components as necessary. Installation 1. Position the new small driveshaft slip-yoke boot clamp on the driveshaft stub shaft. 2. Slide the small opening end of the slip-yoke boot on the driveshaft stub shaft, as far as it will travel. 3. Using the special tool, crimp the driveshaft slip-yoke boot clamp. 4. Install the driveshaft slip-yoke on the driveshaft. 1 Pull the slip-yoke boot toward the driveshaft. Lubricate the driveshaft splines with long-life grease. 2 Position the new large slip-yoke boot clamp. 3 Align the blind splines, and install the driveshaft slip yoke on the driveshaft. 5. Set the driveshaft assembled length to specification. 1 Remove any excess grease from the slip-yoke boot and driveshaft slip-yoke surfaces. 2 Position the slip-yoke boot in the slip-yoke boot groove. 3 Set the driveshaft assembled length to specification. ^ Measure from the stub shaft weld to the U-joint centerline. 4 Bleed the air from the slip-yoke boot. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Rear, One-Piece > Page 4837 6. Using the special tool, crimp the large driveshaft slip-yoke boot clamp. 7. Install the driveshaft. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Universal Joint: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration Universal Joint: Customer Interest Drivetrain - Highway Speed Vibration TSB 07-10-9 05/28/07 VIBRATION FROM THE DRIVELINE AT HIGHWAY SPEEDS FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 06-12-3 to update the vehicle model years. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT vehicles (excluding F-150 Heritage) may exhibit a vibration, felt in the floorpan and/or steering wheel when driven at highway speeds ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Universal Joint: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4846 Refer to the Diagnostic Overview (Figure 1). Based on the customer's description of the concern, find the appropriate Operating Condition, Probable Cause and Repair Action. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Universal Joint: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4847 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Universal Joint: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4848 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Universal Joint: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4849 NOTE IT IS CRITICAL TO IDENTIFY SPECIFIC VEHICLE SPEEDS AND OPERATING CONDITIONS WHEN THE VIBRATION OR NIBBLE IS OCCURRING, TO PROPERLY DIAGNOSE AND REPAIR THE ISSUE. TIRE AND DRIVELINE VIBRATION CAN FEEL SIMILAR. USE OF AN ELECTRONIC VIBRATION ANALYZER (EVA) OR VETRONIX VIBRATION ANALYZER IS RECOMMENDED TO CORRECTLY IDENTIFY VIBRATION SOURCES (ORDERS) AND FREQUENCY (HZ). Parts Block OTHER APPLICABLE ARTICLES: 07-10-08, 06-19-16 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT071009 Claim Labor As Actual Actual Time Or Use SLIS Time Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 4602 42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Universal Joint: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4850 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Universal Joint: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration Universal Joint: All Technical Service Bulletins Drivetrain - Highway Speed Vibration TSB 07-10-9 05/28/07 VIBRATION FROM THE DRIVELINE AT HIGHWAY SPEEDS FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 06-12-3 to update the vehicle model years. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT vehicles (excluding F-150 Heritage) may exhibit a vibration, felt in the floorpan and/or steering wheel when driven at highway speeds ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Universal Joint: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4856 Refer to the Diagnostic Overview (Figure 1). Based on the customer's description of the concern, find the appropriate Operating Condition, Probable Cause and Repair Action. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Universal Joint: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4857 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Universal Joint: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4858 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Universal Joint: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4859 NOTE IT IS CRITICAL TO IDENTIFY SPECIFIC VEHICLE SPEEDS AND OPERATING CONDITIONS WHEN THE VIBRATION OR NIBBLE IS OCCURRING, TO PROPERLY DIAGNOSE AND REPAIR THE ISSUE. TIRE AND DRIVELINE VIBRATION CAN FEEL SIMILAR. USE OF AN ELECTRONIC VIBRATION ANALYZER (EVA) OR VETRONIX VIBRATION ANALYZER IS RECOMMENDED TO CORRECTLY IDENTIFY VIBRATION SOURCES (ORDERS) AND FREQUENCY (HZ). Parts Block OTHER APPLICABLE ARTICLES: 07-10-08, 06-19-16 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT071009 Claim Labor As Actual Actual Time Or Use SLIS Time Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 4602 42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Universal Joint: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 4860 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 4861 Universal Joint: Description and Operation Universal Joints U-joints have the following features: ^ Lubed-for-life design and require no lubrication ^ Equipped with nylon thrust washers (located at each base of the bearing cup) which control end play, position the needle bearing and improve grease movement ^ Held in place by snap rings The U-joints allow the speeding up and slowing down of the driveshafts as the angularity of the driveshaft changes. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 4862 Universal Joint: Service and Repair Driveshaft Universal Joint - Snap Ring Type Disassembly 1. Remove the driveshaft. 2. CAUTION: Do not, under any circumstance, clamp the driveshaft assembly in the jaws of a vise or similar holding fixture. Denting or localized fracturing may result, causing driveshaft failure during vehicle operation. Place the driveshaft on a suitable workbench. Do not damage the tube. 3. NOTE: If the components are not marked and therefore installed incorrectly, driveshaft imbalance can occur. Index-mark the driveshaft components. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 4863 4. Remove and discard all 4 of the snap rings. 5. Place the special tool in a vise. 6. NOTE: If necessary, use a pair of pliers to remove a bearing cup that fails to press out all the way. Remove the bearing cups and the driveshaft slip yoke. 1 Position the driveshaft slip yoke in the special tool. 2 Press out a bearing cup. 3 Rotate the driveshaft slip yoke 180 degrees. 4 Press on the U-joint spider to remove the remaining bearing cup. 5 Remove the driveshaft slip yoke. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 4864 7. Repeat steps to remove the remaining bearing cups and the U-joint spider from the driveshaft yoke. 8. NOTE: Inspect the bearing cup bores and retaining ring grooves. Remove any rust or other surface irregularities. Inspect the bearing cup bores of the driveshaft slip yoke and driveshaft yoke. Make sure that the bearing cup bores are clean and smooth. Assembly 1. NOTE: Install the U-Joint Kits as complete assemblies only. Do not mix components from other U-Joint Kits. NOTE: Lubricate the driveshaft slip yoke and driveshaft yoke bearing cup bores with grease before installing the bearing cups. Install a new U-joint spider and bearing cup. 1 Start a new bearing cup in the driveshaft yoke. ^ Check the needle bearings for correct positioning. 2 Position the new U-joint spider in the driveshaft yoke. 3 Press the bearing cup to just below the snap ring groove. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 4865 2. NOTE: Never mix yellow and black snap rings on opposing sides. Remove the shaft from the special tool and install a new yellow snap ring. 3. Repeat steps to install the new bearing cup and snap ring on the opposite side of the driveshaft yoke. ^ If the yellow snap ring will not seat in the snap ring groove, install the black snap rings. 4. Install the driveshaft slip yoke and new bearing cup. 1 Align the index marks made during disassembly and install the driveshaft slip yoke on the U-joint spider. 2 Start a new bearing cup in the driveshaft slip yoke. ^ Check the needle bearings for correct positioning. 3 Position the assembly in the special tool. 4 Press the bearing cup to just below the snap ring groove. 5. Remove the driveshaft from the special tool and install a new yellow snap ring. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 4866 6. NOTE: Never mix yellow and black snap rings on opposing sides. Repeat steps to install the new bearing cup and snap ring on the opposite side of the driveshaft slip yoke. ^ If the yellow snap ring will not seat in the snap ring groove, install the black snap rings. 7. A sharp rap on the driveshaft yoke with a brass or plastic hammer will seat the bearing cups. 8. Rotate the driveshaft yoke to make sure the U-joints are free to rotate easily, without binding, before installing the driveshaft. 9. Install the driveshaft. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flexplate Bolts First pass ............................................................................................................................................. .................................................... 20 Nm (15 lb-ft). Final pass ............................................................ .................................................................................................................................... 80 Nm (59 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 4870 Flex Plate: Testing and Inspection Flexplate Inspection 1. Inspect the flexplate for: 1 Any cracks. 2 Worn ring gear teeth. 3 Chipped or cracked ring gear teeth. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 4871 Flex Plate: Service and Repair Flexplate Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View Removal 1. Remove the transmission. 2. Remove the 6 flexplate bolts and the flexplate. Installation 1. Install the flexplate and the 6 bolts. Tighten the bolts in 2 stages in the sequence shown. ^ Stage 1: Tighten to 20 Nm (15 lb-ft). ^ Stage 2: Tighten to 80 Nm (59 lb-ft). 2. Install the transmission. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Testing and Inspection > Flywheel Inspection Flywheel: Testing and Inspection Flywheel Inspection Flywheel Inspection 1. NOTE: The flywheel cannot be resurfaced, it must be replaced. Inspect the flywheel for: 1 Any cracks. 2 Worn ring gear teeth. 3 Chipped or cracked ring gear teeth. 4 Scratches, nicks and discoloration. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Testing and Inspection > Flywheel Inspection > Page 4876 Flywheel: Testing and Inspection Flywheel Runout Check Flywheel Runout Check 1. Using the special tool, inspect the flywheel runout. ^ If the pilot bearing is worn or damaged, install a new pilot bearing. ^ Mount the special tool so that the indicator contact point rides on the clutch disc contact surface. Turn the flywheel. ^ If the runout exceeds the maximum allowance, install a new flywheel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments Selector Lever Cable Adjustment Vehicles equipped with a floor mounted selector lever 1. Place the selector lever in the 1st position toward the rear of the vehicle. 2. Move the selector lever forward 2 detents. This should be the (D) position. Vehicles equipped with a column mounted selector lever 3. Rotate the selector lever clockwise until it bottoms out (1st gear), then rotate the selector lever counterclockwise 2 detent positions ((D) position). 4. Hang a 1.4 kg (3 lb) weight on the selector lever. All vehicles 5. With the vehicle in NEUTRAL, position it on a hoist. Vehicles equipped with a floor mounted selector lever 6. Rotate the cable adjustment lock upward and disconnect the selector lever cable from the manual control lever. Vehicles equipped with a column mounted selector lever 7. Slide the selector lever cable adjustment lock upwards and remove the cable from the manual control lever. 8. Rotate the manual control lever forward until the travel stops. Then rotate the manual control lever back 2 detents to the (D) position. Vehicles equipped with a floor mounted selector lever Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments > Page 4882 9. NOTE: Check to be sure that the selector lever cable retainer is correctly installed in the selector lever cable bracket. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the manual control lever and rotate the lock downward to lock the adjuster. Vehicles equipped with a column mounted selector lever 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the manual control lever and slide the lock downward to lock the adjuster. 11. Verify that the engine will start in PARK and NEUTRAL. Verify that the reverse lamps will illuminate in the REVERSE position. If not, check the adjustment of the transmission range (TR) sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transmission Capacity ............................................................................................................................................... ................................................................... 3.7 Quarts Note: Approximate refill. Service refill capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a level surface. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 4891 Fluid - M/T: Fluid Type Specifications Manual Transmission Fluid .................................................................................................................. ......................................................... Mercon V ATF Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Page 4892 Fluid - M/T: Service and Repair Transmission Draining and Filling 1. NOTE: Position a suitable drain pan under the transmission. Remove the drain plug and drain the transmission. 2. Clean and reinstall the drain plug. ^ Tighten to 48 Nm (35 lb-ft). 3. NOTE: Clean the area around the filler plug. Remove the filler plug. 4. NOTE: Fill the transmission with the vehicle on a level surface. Using a suitable oil suction gun, fill the transmission to the correct level with the specified fluid. The fluid must be just below the fill plug hole. ^ Transmission capacity is 3.5L (3.1 qt). 5. Install the filler plug. ^ Tighten to 48 Nm (35 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Flywheel Gear, M/T > Component Information > Service and Repair Flywheel Gear: Service and Repair Flywheel Ring Gear Removal WARNING: This procedure should be carried out only by a correctly equipped and experienced acetylene torch operator. Use tongs or wear welding gloves and safety goggles when handling hot components. Failure to follow these instructions may result in serious personal injury. 1. Remove the flywheel. 2. CAUTION: Tap the flywheel ring gear evenly to prevent binding. Remove the flywheel ring gear from the flywheel. ^ Evenly heat the flywheel ring gear and use a brass drift to drive the flywheel ring gear from the flywheel. Installation 1. CAUTION: Do not heat the flywheel ring gear beyond 278°C (500°F). Use heat indicating crayons to prevent overheating. CAUTION: Keep the torch moving to prevent hot spots. Evenly heat the flywheel ring gear. 2. Install the flywheel ring gear. ^ The bevel on the flywheel ring gear must face the rear of the flywheel. ^ Using a brass drift, install the flywheel ring gear onto the flywheel. 3. Install the flywheel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Description and Operation Power Take-Off: Description and Operation POWER TAKE-OFF (PTO) SWITCH AND CIRCUITS The PTO circuit is used by the PCM to disable some of the on board diagnostics (OBD) monitors during PTO operation. The PTO switch is normally open. When the PTO unit is activated, the PTO switch is closed and battery voltage is supplied to the PTO input circuit. This indicates to the PCM that an additional load is being applied to the engine. The PTO indicator lamp illuminates when the PTO system is functioning correctly and flashes when the PTO system is damaged. When the PTO unit is activated, the PCM disables some OBD monitors, which may not function reliably during PTO operation. Without the PTO circuit information to the PCM, false DTCs may be set during PTO operation. Prior to an Inspection/Maintenance test, operate the vehicle with the PTO disengaged long enough to successfully complete the OBD Monitors. PTO Circuits Description The 3 PTO input circuits are PTO mode, PTO engage, and PTO RPM. The PTO engage circuit is used when the operator is requesting the PCM to check the needed inputs required to initiate the PTO engagement. The PTO RPM circuit is used for the operator to request additional engine RPM for PTO operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay Transfer Case Actuator Relay: Testing and Inspection Counter Clockwise (CCW) Motor 4X4 Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay > Page 4905 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay > Page 4906 Transfer Case Actuator Relay: Testing and Inspection Clockwise (CW) Motor 4X4 Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay > Page 4907 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4914 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4915 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4916 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4917 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4918 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4919 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4920 Brake Switch - TCC: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4921 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4922 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4923 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4924 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4925 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4926 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 4927 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations View 151-19 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4933 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4934 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4935 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4936 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4937 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4938 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4939 Overdrive Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4940 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4941 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4942 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4943 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4944 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4945 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4946 C2135 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions Throttle Position Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 4951 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 4952 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 4953 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 4954 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 4955 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 4956 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 4957 Throttle Position Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 4958 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 4959 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 4960 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 4961 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 4962 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 4963 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Mode Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4968 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4969 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4970 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4971 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4972 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4973 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4974 Transmission Mode Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4975 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4976 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4977 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4978 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4979 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4980 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4981 Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift Transmission Control (TC) Switch - Column Shift Removal and Installation NOTE: The transmission control (TC) switch is part of the transmission range selector lever. 1. To install a new TC switch, a new transmission range selector lever must be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 4984 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Removal 1. Lift the center console lid cover and remove the console finish panel. 2. Depress the bottom of the button. Using a suitable tool, pry forward on the top of the selector lever button and remove the selector lever button. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 4985 3. Remove the screw, slide the selector lever knob up and remove the selector lever knob. 4. Remove the selector lever knob shroud. 5. Disconnect the transmission control (TC) switch electrical connector, release the selector lever bezel locking tabs and remove the selector lever bezel from the selector lever. 6. Release the 2 tabs and push the TC switch through the selector lever bezel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 4986 Installation 1. Install the TC switch in the selector lever bezel. 2. Install the selector lever bezel on the locking tabs and connect the TC switch electrical connector. 3. Install the selector lever knob shroud. 4. CAUTION: Do not overtighten the screw or damage to the selector lever knob can occur. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 4987 Install the selector lever knob and install the screw. 5. Position the selector lever button in place and press in on the top of the selector lever button to install. 6. Install the center console finish panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 Transmission Position Switch/Sensor: Locations View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 4991 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 4994 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 4995 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 4996 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 4997 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 4998 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 4999 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5000 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5001 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5002 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5003 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5004 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5005 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5006 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5007 C167 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 5008 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the selector lever cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 4. Loosen the digital transmission range (TR) sensor bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 5009 5. NOTE: The manual control lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 lb-in). 7. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever shaft outer nut. ^ Tighten to 33 Nm (24 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 5010 8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. With the manual control lever in overdrive connect the selector lever cable. 9. Lower the vehicle. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 5011 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Removal NOTE: The manual control lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the selector lever cable. Disconnect the selector lever cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 5012 3. Disconnect the digital transmission range (TR) electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 5013 Installation 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 5014 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 lb-ft). 5. Connect the digital TR sensor electrical connector. 6. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable end to the manual control lever with the lever in the (D) position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 5015 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Locations Output Shaft Speed (OSS) Sensor View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5020 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5021 View 151-12 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5022 Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5023 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5026 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5027 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5028 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5029 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5030 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5031 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5032 Transmission Speed Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5033 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5034 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5035 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5036 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5037 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5038 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5039 Transmission Speed Sensor: Connector Views C193 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5040 C1107 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5041 C143 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 3. Remove the TSS sensor bolt and sensor. ^ Remove the TSS sensor bolt. ^ Remove the TSS sensor. 4. To install, reverse the removal procedure. ^ Tighten bolt to 11 Nm (8 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 5044 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the output shaft speed (OSS) sensor electrical connector. 3. Remove the OSS sensor bolt and sensor. ^ Remove the OSS sensor bolt. ^ Remove the OSS sensor. 4. To install, reverse the removal procedure. ^ Tighten bolt to 12 Nm (9 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5049 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5050 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5051 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5052 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5053 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5054 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5055 Transmission Temperature Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5056 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5057 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5058 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5059 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5060 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5061 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay Transfer Case Actuator Relay: Testing and Inspection Counter Clockwise (CCW) Motor 4X4 Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay > Page 5068 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay > Page 5069 Transfer Case Actuator Relay: Testing and Inspection Clockwise (CW) Motor 4X4 Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay > Page 5070 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay Transfer Case Actuator Relay: Testing and Inspection Counter Clockwise (CCW) Motor 4X4 Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay > Page 5075 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay > Page 5076 Transfer Case Actuator Relay: Testing and Inspection Clockwise (CW) Motor 4X4 Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay > Page 5077 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5085 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5086 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5087 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5088 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5089 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5090 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5091 Pressure Regulating Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5092 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5093 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5094 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5095 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5096 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5097 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5098 Pressure Regulating Solenoid: Service and Repair Electronic Pressure Control (EPC) Solenoid Removal CAUTION: Do not pull on the molded lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. Disconnect the molded lead frame from the solenoids. 1 Disconnect the shift solenoid SSA and SSB. 2 Disconnect the torque converter clutch (TCC). 3 Disconnect the electronic pressure control (EPC) solenoid. 4 Disconnect the bulkhead interconnector. 4. Remove the EPC solenoid. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5099 Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 lb-in). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame. 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5100 4. Install the transmission fluid pan and filter. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams C2008 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Floor Shift Brake Shift Interlock Actuator - Floor Shift Brake Shift Interlock Actuator (BSIA) - Floor Shift Removal 1. Remove the floor console left side kick panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 5106 2. Lift the console storage lid cover and remove the console finish panel. 3. Disconnect the selector lever cable from the arm of the selector lever. 4. Disconnect the selector lever cable from the selector lever cable bracket on the selector lever. 5. Remove the selector lever bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 5107 6. Disconnect the selector lever electrical connector and remove the selector lever from the vehicle. 7. Disconnect the electrical connector. 1 Disconnect the overdrive cancel button electrical connector. 2 Cut the tie strap holding the wire harness to the base of the selector lever. 8. Remove the brake shift interlock actuator (BSIA). 1 Remove the bulb from the housing. 2 Cut the tie strap from the wire harness. 3 Remove the 2 screws and remove the BSIA. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 5108 Installation 1. Install the BSIA. 1 Install the BSIA and install the 2 screws. 2 Install the bulb into the housing. 3 Install a new tie strap on the wire harness. 2. Connect the electrical connector. 1 Connect the overdrive cancel button electrical connector. 2 Install a new tie strap to the wire harness. 3. Position the selector lever assembly in the console and install the bolts. ^ Tighten to 12 Nm (9 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 5109 4. Connect the selector lever electrical connector. 5. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Install the selector lever cable in the selector lever cable bracket. 6. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the selector lever arm. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 5110 7. Install the console finish panel. 8. Install the left console kick panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 5111 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator - Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the steering wheel. 3. Remove the 2 screws and the lower dash panel. 4. Remove the screw and the lower steering column shroud. 5. Remove the 2 screws and the upper steering column shroud. 6. Disconnect the clockspring electrical connectors. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 5112 7. Remove the screw and slide the multi-function switch up and position it aside. 8. Place a piece of tape on the clockspring to prevent it from rotating. 9. Press the 3 tabs on the clockspring and slide the clockspring off. 10. Remove the 3 screws and remove the clockspring and shroud mounting bracket. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Brake Shift Interlock Actuator - Floor Shift > Page 5113 11. Disconnect the brake shift interlock switch electrical connector. 12. Release the tab and slide the brake shift interlock down to remove. 13. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5118 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5119 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5120 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5121 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5122 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5123 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5124 Shift Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5125 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5126 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5127 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5128 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5129 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5130 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5131 Shift Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the shift solenoid operation information when carrying out Pinpoint Test A. See: Testing and Inspection/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5132 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always Off" Failed off due to PCM and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5133 Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Pinpoint Tests Refer to Vehicle/Diagrams for schematic and connector information. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5138 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5139 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5140 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5141 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5142 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5143 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5144 Torque Converter Clutch Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5145 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5146 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5147 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5148 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5149 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5150 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments Selector Lever Cable Adjustment Vehicles equipped with a floor mounted selector lever 1. Place the selector lever in the 1st position toward the rear of the vehicle. 2. Move the selector lever forward 2 detents. This should be the (D) position. Vehicles equipped with a column mounted selector lever 3. Rotate the selector lever clockwise until it bottoms out (1st gear), then rotate the selector lever counterclockwise 2 detent positions ((D) position). 4. Hang a 1.4 kg (3 lb) weight on the selector lever. All vehicles 5. With the vehicle in NEUTRAL, position it on a hoist. Vehicles equipped with a floor mounted selector lever 6. Rotate the cable adjustment lock upward and disconnect the selector lever cable from the manual control lever. Vehicles equipped with a column mounted selector lever 7. Slide the selector lever cable adjustment lock upwards and remove the cable from the manual control lever. 8. Rotate the manual control lever forward until the travel stops. Then rotate the manual control lever back 2 detents to the (D) position. Vehicles equipped with a floor mounted selector lever Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments > Page 5156 9. NOTE: Check to be sure that the selector lever cable retainer is correctly installed in the selector lever cable bracket. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the manual control lever and rotate the lock downward to lock the adjuster. Vehicles equipped with a column mounted selector lever 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the manual control lever and slide the lock downward to lock the adjuster. 11. Verify that the engine will start in PARK and NEUTRAL. Verify that the reverse lamps will illuminate in the REVERSE position. If not, check the adjustment of the transmission range (TR) sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay Transfer Case Actuator Relay: Testing and Inspection Counter Clockwise (CCW) Motor 4X4 Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay > Page 5166 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay > Page 5167 Transfer Case Actuator Relay: Testing and Inspection Clockwise (CW) Motor 4X4 Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Transfer Case Actuator Relay > Component Information > Testing and Inspection > Counter Clockwise (CCW) Motor 4X4 Relay > Page 5168 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5175 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5176 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5177 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5178 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5179 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5180 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5181 Brake Switch - TCC: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5182 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5183 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5184 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5185 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5186 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5187 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Page 5188 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations View 151-19 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5194 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5195 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5196 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5197 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5198 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 Overdrive Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5202 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5205 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5206 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5207 C2135 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions Throttle Position Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5212 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5213 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5214 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5215 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5216 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5217 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5218 Throttle Position Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5219 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5220 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5221 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5222 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5223 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5224 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions Transmission Mode Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5229 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5230 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5231 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5232 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5233 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5234 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5235 Transmission Mode Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5236 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5237 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5238 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5239 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5240 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5241 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Page 5242 Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Service and Repair > Transmission Control (TC) Switch - Column Shift Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Column Shift Transmission Control (TC) Switch - Column Shift Removal and Installation NOTE: The transmission control (TC) switch is part of the transmission range selector lever. 1. To install a new TC switch, a new transmission range selector lever must be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 5245 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Transmission Control (TC) Switch - Floor Shift Removal 1. Lift the center console lid cover and remove the console finish panel. 2. Depress the bottom of the button. Using a suitable tool, pry forward on the top of the selector lever button and remove the selector lever button. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 5246 3. Remove the screw, slide the selector lever knob up and remove the selector lever knob. 4. Remove the selector lever knob shroud. 5. Disconnect the transmission control (TC) switch electrical connector, release the selector lever bezel locking tabs and remove the selector lever bezel from the selector lever. 6. Release the 2 tabs and push the TC switch through the selector lever bezel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 5247 Installation 1. Install the TC switch in the selector lever bezel. 2. Install the selector lever bezel on the locking tabs and connect the TC switch electrical connector. 3. Install the selector lever knob shroud. 4. CAUTION: Do not overtighten the screw or damage to the selector lever knob can occur. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Service and Repair > Transmission Control (TC) Switch - Column Shift > Page 5248 Install the selector lever knob and install the screw. 5. Position the selector lever button in place and press in on the top of the selector lever button to install. 6. Install the center console finish panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 Transmission Position Switch/Sensor: Locations View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 5252 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5255 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5256 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5257 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5258 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5259 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5260 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5261 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5262 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5263 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5264 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5265 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5266 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5267 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagram Information and Instructions > Page 5268 C167 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 5269 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the selector lever cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 4. Loosen the digital transmission range (TR) sensor bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 5270 5. NOTE: The manual control lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 lb-in). 7. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever shaft outer nut. ^ Tighten to 33 Nm (24 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 5271 8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. With the manual control lever in overdrive connect the selector lever cable. 9. Lower the vehicle. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 5272 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Removal NOTE: The manual control lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the selector lever cable. Disconnect the selector lever cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 5273 3. Disconnect the digital transmission range (TR) electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 5274 Installation 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 5275 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 lb-ft). 5. Connect the digital TR sensor electrical connector. 6. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable end to the manual control lever with the lever in the (D) position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Page 5276 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Locations Output Shaft Speed (OSS) Sensor View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5281 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5282 View 151-12 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5283 Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5284 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5287 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5288 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5289 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5290 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5291 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5292 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5293 Transmission Speed Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5294 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5295 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5296 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5297 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5298 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5299 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5300 Transmission Speed Sensor: Connector Views C193 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5301 C1107 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5302 C143 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 3. Remove the TSS sensor bolt and sensor. ^ Remove the TSS sensor bolt. ^ Remove the TSS sensor. 4. To install, reverse the removal procedure. ^ Tighten bolt to 11 Nm (8 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 5305 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the output shaft speed (OSS) sensor electrical connector. 3. Remove the OSS sensor bolt and sensor. ^ Remove the OSS sensor bolt. ^ Remove the OSS sensor. 4. To install, reverse the removal procedure. ^ Tighten bolt to 12 Nm (9 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5310 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5311 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5312 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5313 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5314 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5315 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5316 Transmission Temperature Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5317 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5318 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5319 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5320 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5321 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 > Diagrams > Diagram Information and Instructions > Page 5322 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Differential Speed Sensor > Component Information > Locations View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Differential Speed Sensor > Component Information > Locations > Page 5328 C455 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations View 151-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5332 C135 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5333 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Anti-Lock Brake System (ABS) Module Removal and Installation CAUTION: Electronic modules are sensitive to electrical charges. The anti-lock brake system (ABS) module can be damaged if exposed to these charges. CAUTION: When installing a new anti-lock brake system (ABS) module or hydraulic control unit (HCU), do not use the pump motor harness as a carrying handle. Failure to follow these instructions may result in damage to the HCU assembly. All vehicles 1. Disconnect the battery ground cable. For additional information, refer to Battery. Vehicles equipped with 5.4L engine 2. Remove the air cleaner intake pipe. For additional information, refer to Fuel Delivery and Air Induction. All vehicles 3. Disconnect the ABS module electrical connector. 4. Remove the 4 screws and the ABS module. ^ To install, tighten to 3 Nm (27 lb-in). 5. NOTE: The ABS module is not repairable. If an internal problem exists, a new part must be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5334 To install, reverse the removal procedure. When installing a new ABS module, it must be configured (using vehicle as-built data) and calibrated. Follow the scan tool directions for calibration procedures. For additional information on configuration, refer to Information Bus (Module Configuration). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) Material Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 5338 Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. 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. CAUTION: Electronic modules are sensitive to electrical charges. The anti-lock brake system (ABS) module can be damaged if exposed to these charges. CAUTION: When installing a new anti-lock brake system (ABS) module or hydraulic control unit (HCU), do not use the pump motor harness as a carrying handle. Failure to follow these instructions may result in damage to the HCU assembly. CAUTION: When disconnecting the brake tubes, do not allow brake fluid to drip onto the anti-lock brake system (ABS) module or premature failure may occur. CAUTION: Do not allow brake fluid to drip into the anti-lock brake system (ABS) module electrical connector cavity or premature failure may occur. All vehicles 1. Disconnect the battery ground cable. For additional information, refer to Battery. Vehicles equipped with 5.4L engine 2. Remove the air cleaner intake pipe. For additional information, refer to Fuel Delivery and Air Induction. Vehicles equipped with 4.6L and 4.2L engine 3. Remove the air cleaner assembly. For additional information, refer to Fuel Delivery and Air Induction. All vehicles 4. NOTE: The brake tubes must be installed in the same location as removed. Remove the 5 brake tube-to-hydraulic control unit (HCU) fittings. ^ To install, tighten to 22 Nm (16 lb-ft). 5. Remove the 2 HCU-to-bracket nuts and the HCU. ^ To install, tighten to 8 Nm (71 lb-in). 6. Remove the ABS module. 7. NOTE: The HCU bracket does not have to be removed in order to complete this procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 5339 If necessary, remove the 3 HCU-bracket-to-frame bolts and the bracket. ^ To install, tighten to 30 Nm (22 lb-ft). 8. To install, reverse the removal procedure. ^ Bleed the brake system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations View 151-14 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 5343 C280 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front View 151-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 5348 View 151-2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front C150 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 5351 C160 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor - Front, Rear Wheel Drive (RWD) Wheel Speed Sensor - Front, Rear Wheel Drive (RWD) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. NOTE: The harness connector is located in the engine compartment secured to the fender apron. Disconnect the wheel speed sensor electrical connector. 3. Disconnect the 2 wheel speed sensor harness retainers from the brake hose. 4. Remove the wheel speed sensor harness from the pushpin retainer. 5. Remove the bolt and the wheel speed sensor. ^ To install, tighten to 8 Nm (71 lb-in). 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5354 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Disconnect the wheel speed sensor electrical connector. 3. Remove the wheel speed sensor bolt. ^ To install, tighten to 15 Nm (11 lb-ft). 4. NOTE: Install a new O-ring before installing the rear axle speed sensor. Remove the wheel speed sensor. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding Brake Bleeding: Service and Repair Component Bleeding Component Bleeding Material Master Cylinder WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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. NOTE: When a new brake master cylinder has been installed or the system has been emptied or partially emptied, it should be primed to prevent air from getting into the system. 1. Disconnect the brake master cylinder outlet tubes. 2. NOTE: Original equipment tubes are not intended to be used during this procedure. Install short brake tubes with the ends submerged into the brake master cylinder reservoir and fill the brake master cylinder reservoir with clean, specified brake fluid. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 5359 3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air bubbles. 4. Remove the short brake tubes and install the brake outlet tubes. 5. Bleed each brake tube at the brake master cylinder in the following sequence: 1 Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2 Loosen the rear brake tube fitting until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the brake tube fitting. 3 Repeat this operation until clear, bubble-free fluid comes out. 4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation for the front brake tube. 6. While the assistant maintains pressure on the brake pedal, tighten the brake tube fittings. ^ Tighten to 18 Nm (13 lb-ft). Brake Caliper WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If spilled, wipe up immediately before damage to the painted or plastic surface occurs. 1. Remove the brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the brake caliper bleeder screw to 20 Nm (15 lb ft), remove the rubber hose and install the bleeder screw cap. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 5360 Brake Bleeding: Service and Repair Brake System Bleeding Brake System Bleeding Special Tool(s) Material WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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. NOTE: When the hydraulic control unit (HCU) or master cylinder is disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: Pressure bleed the brake system at 207-345 kPa (30-50 psi). NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. 1. Clean all the dirt from around the brake fluid reservoir cap and remove the cap. Fill the brake master cylinder reservoir with clean, specified brake fluid. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 5361 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough clean, specified brake fluid to complete the bleeding operation. Remove the RH rear brake caliper bleeder cap and place a box end wrench on the bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear brake caliper bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw. ^ Press and release the parking brake 5 times. ^ Repeat until clear, bubble-free fluid comes out. 6. Tighten the RH rear brake caliper bleeder screw to 20 Nm (15 lb-ft), remove the rubber hose and install the bleeder screw cap. 7. Repeat Steps 5 and 6 for the LH rear brake caliper. ^ Tighten the LH rear brake caliper bleeder screw to 20 Nm (15 lb-ft). 8. Continue bleeding the front of the system, going in order from the RH front brake caliper and then to the LH front brake caliper. ^ Tighten the front brake caliper bleeder screws to 20 Nm (15 lb ft). 9. Close the bleeder tank valve. Remove the tank hose from the adapter and remove the adapter. Fill the reservoir with clean, specified brake fluid and install the reservoir cap. Manual Bleeding WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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. NOTE: When the hydraulic control unit (HCU) or master cylinder is disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with clean, specified brake fluid. 2. NOTE: Bleed the brake system from the longest to the shortest brake line. Remove the RH rear brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 5362 4. Loosen the RH rear brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 5. Tighten the RH rear brake caliper bleeder screw to 20 Nm (15 lb-ft), remove the rubber hose and install the bleeder screw cap. 6. Repeat Steps 2 through 5 for the LH rear brake caliper bleeder screw. ^ Tighten the LH rear brake caliper bleeder screw to 20 Nm (15 lb-ft). 7. Remove the RH front brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9. Loosen the RH front brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 10. Tighten the RH front brake caliper bleeder screw to 20 Nm (15 lb-ft), remove the rubber hose and install the bleeder screw cap. 11. Repeat Steps 7 through 10 for the LH front brake caliper bleeder screw. ^ Tighten the LH front brake caliper bleeder screw to 20 Nm (15 lb-ft). ABS Hydraulic Control Unit (HCU) Bleeding WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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. NOTE: When the hydraulic control unit (HCU) or master cylinder is disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: This procedure is only required when a new HCU is installed. 1. NOTE: Carrying out the System Bleed function drives trapped air from the HCU. Subsequent bleeding removes the air from the brake hydraulic system through the bleeder screws. NOTE: Adequate voltage to the HCU module is required during the anti-lock control portion of the system bleed. Connect the scan tool to the vehicle. 2. Access the ABS HCU bleed function and follow the directions on the scan tool. 3. Manually bleed the brake hydraulic system. 4. Repeat the procedure carrying out a total of 2 scan tool cycles and 2 manual bleed cycles. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Customer Interest for Brake Pedal Assy: > 10-24-11 > Dec > 10 > Interior - Adjustable Pedals Rattle Brake Pedal Assy: Customer Interest Interior - Adjustable Pedals Rattle TSB 10-24-11 12/16/10 RATTLE NOISE FROM ADJUSTABLE PEDAL ASSEMBLY FORD: 2006-2008 F-150 ISSUE Some 2006-2008 F-150 vehicles equipped with adjustable pedals may exhibit a rattle type noise going over bumps coming from the pedal assembly area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Order the Service Kit and follow the instruction sheet. This kit requires the use of two (2) Loctite(R) chemicals which need to be obtained locally. ^ Loctite(R) 7649(TM) Primer N(TM) (1.75 oz. bottle) ^ Loctite(R) 648(TM) Retaining Compound (10 ml bottle) Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102411A 2006-2008 F-150: Replace 1.4 Hrs. Slot Bushing, Includes Time To Remove And Install Brake Pedal And Bracket Assembly (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 2455 30 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pedal Assy: > 10-24-11 > Dec > 10 > Interior - Adjustable Pedals Rattle Brake Pedal Assy: All Technical Service Bulletins Interior - Adjustable Pedals Rattle TSB 10-24-11 12/16/10 RATTLE NOISE FROM ADJUSTABLE PEDAL ASSEMBLY FORD: 2006-2008 F-150 ISSUE Some 2006-2008 F-150 vehicles equipped with adjustable pedals may exhibit a rattle type noise going over bumps coming from the pedal assembly area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Order the Service Kit and follow the instruction sheet. This kit requires the use of two (2) Loctite(R) chemicals which need to be obtained locally. ^ Loctite(R) 7649(TM) Primer N(TM) (1.75 oz. bottle) ^ Loctite(R) 648(TM) Retaining Compound (10 ml bottle) Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 102411A 2006-2008 F-150: Replace 1.4 Hrs. Slot Bushing, Includes Time To Remove And Install Brake Pedal And Bracket Assembly (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 2455 30 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal and Bracket Brake Pedal Assy: Service and Repair Brake Pedal and Bracket Brake Pedal and Bracket Brake Pedal and Bracket Removal and Installation NOTE: Adjustable pedal assembly shown, fixed pedal assembly similar. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal and Bracket > Page 5378 1. If equipped with adjustable pedals, position them to the full forward position. 2. Remove the instrument panel steering column cover. For additional information, refer to Dash Board. 3. NOTE: The accelerator pedal and the brake pedal must be in the same position before connecting the adjustable accelerator pedal cable. If equipped, disconnect the adjustable accelerator pedal cable from the accelerator pedal assembly and position it aside. 4. CAUTION: Do not service the brake pedal or brake booster without first removing the stop lamp switch and speed control deactivator switch. These switches must be removed with the brake pedal in the at-rest position. Switch plungers must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) will result in damage to the switch. If equipped, remove the speed control deactivator switch. For additional information, refer to Cruise Control. 5. Remove the stop lamp switch. For additional information, refer to Lighting and Horns. 6. If equipped with adjustable pedals, disconnect the adjustable pedal motor electrical connector at the top of the bracket. 7. Remove the 4 brake booster nuts. ^ To install, tighten to 25 Nm (18 lb-ft). 8. Remove the 2 upper brake pedal bracket bolts and the brake pedal and bracket assembly. ^ To install, tighten to 25 Nm (18 lb-ft). 9. CAUTION: Do not press, pull or otherwise move the brake pedal while installing the stop lamp switch or the speed control deactivator switch. These switches must be installed with the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position. Installing these switches with the brake pedal in any other position will result in incorrect adjustment and may damage the switches. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal and Bracket > Page 5379 Brake Pedal Assy: Service and Repair Brake Pedal Motor Cable Brake Pedal Motor Cable Removal and Installation 1. NOTE: The accelerator pedal and the brake pedal must be in the same position before connecting the adjustable brake pedal cable. Release the brake pedal motor cable from the brake pedal transmission assembly. 2. Release the brake pedal motor cable from the brake pedal motor. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Testing and Inspection > Brake Calipers Brake Caliper: Testing and Inspection Brake Calipers Brake System Inspection Brake Calipers 1. Inspect the brake calipers for leaks, damage to seals and piston corrosion or binding. - If the brake caliper is leaking or otherwise damaged, install a new brake caliper. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Testing and Inspection > Brake Calipers > Page 5385 Brake Caliper: Testing and Inspection Brake Caliper Guide Pins Brake Caliper Guide Pins NOTICE: Do not use power tools for caliper guide pin bore cleaning. Damage to the bore may result. NOTE: The guide pins are part of the anchor plate. The guide pins should slide with a reasonable amount of hand force. If the brake pads show taper wear or the guide pins are difficult to move install a new brake caliper anchor plate. See: Service and Repair If the lining is not within specifications install new brake pads. See: Brake Pad/Service and Repair Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front Brake Caliper: Service and Repair Caliper Removal and Installation, Front Brake Caliper Material Removal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 5388 Disc Brake System - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 5389 Disc Brake System - Exploded View (Part 2) WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. 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. 1. Remove the wheel and tire. 2. Remove the brake caliper flow bolt and discard the 2 copper washers. 3. Remove the 2 brake caliper guide pin bolts and the brake caliper. Installation 1. Using 2 new copper washers, position the brake flexible hose on the brake caliper and install the brake caliper flow bolt. ^ Tighten to 35 Nm (26 lb-ft). 2. NOTE: Tighten the lower caliper guide pin bolt first. Position the brake caliper on the brake caliper anchor plate and install the 2 guide pin bolts. ^ Tighten to 74 Nm (55 lb-ft). 3. Bleed the brake caliper. 4. Install the wheel and tire. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 5390 Brake Caliper: Service and Repair Caliper Removal and Installation, Rear Brake Caliper Material Removal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 5391 Disc Brake System - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 5392 Disc Brake System - Exploded View (Part 2) WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. 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. 1. Remove the wheel and tire. 2. Remove the brake caliper flow bolt and discard the 2 copper washers. 3. Remove the 2 guide pin bolts and the brake caliper. Installation 1. Position the brake caliper and install the 2 guide pin bolts. ^ Tighten to 30 Nm (22 lb-ft). 2. Using 2 new copper washers, position the brake hose on the brake caliper and install the flow bolt. ^ Tighten to 35 Nm (26 lb-ft). 3. Bleed the brake caliper. See: Brake Bleeding 4. Install the wheel and tire. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 5393 Brake Caliper: Service and Repair Brake Caliper Anchor Plate, Front Brake Caliper Anchor Plate Material Removal and Installation Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 5394 Disc Brake System - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 5395 Disc Brake System - Exploded View (Part 2) 1. Remove the brake pads. 2. Remove and discard the 2 brake caliper anchor plate bolts. ^ To install, tighten the new bolts to 200 Nm (148 lb-ft). 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Mechanical Specifications Brake Pad: Mechanical Specifications Brake Pads Maximum pad taper wear (in any direction) ...................................................................................................................................... 3.0 mm (0.118 inch) Minimum pad thickness ................................................................................................... .................................................................. 3.0 mm (0 118 inch) Maximum brake pad thickness variation (pad-to-pad) ................................................................................................................... 18.5 mm (0.0728 inch) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Mechanical Specifications > Page 5400 Brake Pad: Capacity Specifications Material Material Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Mechanical Specifications > Page 5401 Brake Pad: Fluid Type Specifications Material Material Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 5402 Brake Pad: Testing and Inspection Brake Pads NOTE: It is not required to install new brake pads if friction material properties are within guidelines. It is also not required to install new brake pads when the brake discs are machined. ^ Remove the brake pads. Refer to rear disc brakes. ^ Inspect and measure the thickness of the brake pad friction material. ^ Install new brake pads if the thickness of the friction material is less than 3.0 mm (0.118 inch). Refer to the rear disc brakes. See: Specifications ^ Compare all 4 front or rear pads for uneven wear. Install new brake pads if the thickness of the friction material varies from pad to pad by more than 2.0 mm (0.079 inch). Refer to the rear disc brakes. See: Specifications ^ Install new brake pads if there are missing chunks or cracks in the lining through to the backing plate. Refer to for the front disc brakes or for the rear disc brakes. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures Brake Pad: Procedures Brake Pads Removal WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. WARNING: always install new brake shoes or pads at both ends of an axle to reduce the possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in uneven braking and serious personal injury. 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. 1. Check the brake fluid level in the brake master cylinder reservoir. - If required, remove fluid until the brake master cylinder reservoir is half full. 2. With the vehicle in NEUTRAL, position it on a hoist. CAUTION: Install a new pad if it is worn past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. 3. Inspect the pads for wear and contamination. CAUTION: Do not allow the brake caliper to hang from the brake caliper flexible hose. Use a suitable tool to support the brake caliper. 4. Remove the 2 brake caliper guide pin bolts and position the brake caliper aside. - Support the caliper using mechanic's wire. 5. Measure the brake disc thickness and install a new brake disc if it is not within specification. 6. Remove the brake pads and the 2 slippers. - Discard the slippers. 7. Inspect the disc brake anchor plate assembly. - Check the guide pin boots for damage. - Check the guide pins for binding and damage. - Replace worn or damaged boots. Lubricate the guide pins. Installation NOTICE: Protect the caliper pistons and boots when pushing the caliper piston into the caliper piston bores or damage to components may occur. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the pad lining material. Do not install contaminated pads. NOTE: Install all new hardware supplied with the pad kit. 1. Install the 2 new slippers and brake pads. 2. Position the brake caliper and install the 2 bolts. - Tighten to 30 Nm (22 lb-ft). 3. Fill the master cylinder with clean specified brake fluid. 4. Apply brakes several times to verify correct brake operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5405 Brake Pad: Removal and Replacement Disc Brake System - Exploded View Disc Brake System - Exploded View Disc Brake System - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5406 Disc Brake System - Exploded View (Part 2) Brake Pads Brake Pads Removal WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. WARNING: always install new brake shoes or pads at both ends of an axle to reduce the possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in uneven braking and serious personal injury. 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. 1. Check the brake fluid level in the brake master cylinder reservoir. - If required, remove fluid until the brake master cylinder reservoir is half full. 2. With the vehicle in NEUTRAL, position it on a hoist. CAUTION: Install a new pad if it is worn past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. 3. Inspect the pads for wear and contamination. CAUTION: Do not allow the brake caliper to hang from the brake caliper flexible hose. Use a suitable tool to support the brake caliper. 4. Remove the 2 brake caliper guide pin bolts and position the brake caliper aside. - Support the caliper using mechanic's wire. 5. Measure the brake disc thickness and install a new brake disc if it is not within specification. 6. Remove the brake pads and the 2 slippers. - Discard the slippers. 7. Inspect the disc brake anchor plate assembly. - Check the guide pin boots for damage. - Check the guide pins for binding and damage. - Replace worn or damaged boots. Lubricate the guide pins. Installation NOTICE: Protect the caliper pistons and boots when pushing the caliper piston into the caliper piston bores or damage to components may occur. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5407 CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the pad lining material. Do not install contaminated pads. NOTE: Install all new hardware supplied with the pad kit. 1. Install the 2 new slippers and brake pads. 2. Position the brake caliper and install the 2 bolts. - Tighten to 30 Nm (22 lb-ft). 3. Fill the master cylinder with clean specified brake fluid. 4. Apply brakes several times to verify correct brake operation. Front Brake Pads Material Removal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5408 Disc Brake System - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5409 Disc Brake System - Exploded View (Part 2) WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Always install new brake shoes or pads at both ends of an axle to reduce the possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in uneven braking and serious personal injury. 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. 1. Check the brake fluid level in the brake master cylinder reservoir. ^ If necessary, remove fluid until the brake master cylinder reservoir is half full. 2. Remove the wheel and tire. 3. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper guide pin bolts and position the caliper aside. ^ Support the caliper using mechanic's wire. 4. Remove the brake pads and the 2 spring clips. 5. Inspect the brake pads for wear and contamination. Installation 1. NOTE: One brake disc pad kit contains the pads required for both the RH and LH side. Install the new spring clips and brake pads. 2. NOTE: Protect the pistons and boots when compressing the piston into its bore. Using a suitable tool, compress the disc brake caliper pistons into the brake caliper bore. 3. NOTE: Tighten the lower caliper guide pin bolt first. Position the brake caliper on the brake caliper anchor plate and install the 2 guide pin bolts. ^ Tighten to 74 Nm (55 lb-ft). 4. Install the wheel and tire. ^ Apply brakes several times to verify correct brake operation. Rear Brake Pads Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5410 Material Removal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5411 Disc Brake System - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5412 Disc Brake System - Exploded View (Part 2) WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Always install new brake shoes or pads at both ends of an axle to reduce the possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in uneven braking and serious personal injury. 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. 1. Check the brake fluid level in the brake master cylinder reservoir. ^ If required, remove fluid until the brake master cylinder reservoir is half full. 2. Remove the wheel and tire. 3. CAUTION: Do not allow the brake caliper to hang from the brake hose or damage to the hose can result. Remove the 2 brake caliper guide pin bolts and position the brake caliper aside. ^ Support the caliper using mechanic's wire. 4. Measure the brake disc thickness and install a new brake disc if it is not within specification. 5. Remove the brake pads and the 2 slippers. ^ Discard the slippers. Installation 1. CAUTION: Protect the caliper pistons and boots when pushing the caliper piston into the caliper piston bores or damage to components may occur. Using a C-clamp and a worn brake pad, compress the caliper piston into the caliper. 2. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the pad lining material or damage to components may occur. Do not install contaminated pads. NOTE: Install all new hardware supplied with the pad kit and spring kit. Install the 2 new slippers and brake pads. 3. Position the brake caliper and install the 2 guide pin bolts. 4. Fill the master cylinderr with clean specified brake fluid. ^ Tighten to 30 Nm (22 lb-ft). 5. Install the wheel and tire. ^ Apply brakes several times to verify correct brake operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Mechanical Specifications Brake Rotor/Disc: Mechanical Specifications Front Brake Disc Minimum thickness .............................................................................................................................. ............................................ 28.5 mm (1.122 inch) Minimum thickness to machine ....................................................................................................................................................... 29.1 mm (1.145 inch) Rear Brake Disc Minimum thickness .............................................................................................................................. .............................................. 18.5 mm (0.72 inch) Minimum thickness to machine ......................................................................................................................................................... 19.1 mm (0.75 inch) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Mechanical Specifications > Page 5417 Brake Rotor/Disc: Capacity Specifications Material Material Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Mechanical Specifications > Page 5418 Brake Rotor/Disc: Fluid Type Specifications Material Material Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5419 Brake Rotor/Disc: Description and Operation Rear Disc Brake The rear disc brake system consists of the following components: ^ Brake caliper anchor plate ^ Brake caliper ^ Brake disc ^ Brake disc shield ^ Brake flexible hose ^ Brake pads When mechanical force is applied by the driver to the brake pedal, the force is converted into hydraulic pressure by the master cylinder. The hydraulic force is directed to the disc brake calipers and transferred to the brake pads. The brake pads are then forced against the brake friction surfaces by the brake caliper pistons. The friction of the brake pads on the brake disc causes the slowing or stopping of wheel rotation and the vehicle. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5420 Brake Rotor/Disc: Testing and Inspection Brake System Inspection Brake Discs NOTICE: Using an impact tool without a torque socket will lead to unevenly tightened wheel nuts. This causes brake disc on-vehicle lateral runout and brake roughness. 1. Inspect the brake discs and measure the brake disc thickness. Record the measurement. Refer to Specifications. - If the brake disc is cracked or otherwise damaged, install a new brake disc. - If the measurement is below the minimum thickness specification, install a new brake disc. - If the diagnosis has revealed vibration in the steering wheel, seat or pedal while braking that varies with vehicle speed, machine the brake disc. Heavily scored brake discs, similar to that caused by pads worn down to the backing plate, should also be machined. In order to machine, discs must be above the minimum thickness specification. For additional information, refer to Specifications and Brake Disc Machining See: Service and Repair/Procedures. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures Brake Rotor/Disc: Procedures Brake Disc Machining Disc Brake System - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5423 Disc Brake System - Exploded View (Part 2) Material NOTE: Do not use a bench lathe to machine the brake discs. NOTE: Read the entire operating manual and/or view the video shipped with the lathe before installing, operating or repairing the lathe. NOTE: If the thickness of the brake disc is less than the minimum thickness to machine specification, install a new brake disc. This will make sure that the brake disc will be above minimum thickness after machining. NOTE: Do not machine new brake discs. NOTE: Lateral runout and disc thickness variation measurements are not required because correct adjustment of the on-vehicle brake lathe will make sure that these dimensions are within specifications. 1. NOTE: It is not necessary to disconnect the brake tube from the brake caliper. Position the brake caliper and brake caliper anchor bracket aside. 2. For vehicles with a 2-piece brake disc and hub assembly, carry out the steps in the following order. 1 Mark the brake disc and the wheel stud for correct indexing during re-assembly. 2 Remove the brake disc from the hub. 3 CAUTION: Do not use an abrasive sanding disc since it will remove paint or other protective finishes from the wheel or metal from the mounting surfaces, adversely affecting corrosion protection and brake disc lateral runout. Remove corrosion from the wheel mounting surface, both disc mounting surfaces and hub mounting surface. 4 Align the marks and install the brake disc on the hub. 3. Machine the brake disc using an on-vehicle brake lathe. Carry out the steps in the following order. 1 Install the hub adapter and silencer belt if necessary. 2 Install the cutting lathe. 3 If the lathe is not self adjusting, adjust the lathe oscillation using a dial indicator. Total indicated reading (TIR) target is 0.000 mm (0.000 inch), maximum is 0.08 mm (0.003 inch). 4 Center the cutting head, adjust the cutting bits and install the chip deflector. 5 NOTE: The depth of cut should be between 0.10 and 0.20 mm (0.004 and 0.008 inch). Lighter cuts will cause the bit to heat up and wear faster. Heavier cuts will cause poor brake disc surface finish. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5424 Machine the brake disc. 6 Remove the lathe and, if installed, the silencer belt. 7 Remove the hub adapter. 4. Remove the metal shavings. 5. For vehicles with a 2-piece brake disc and hub assembly carry out the steps in the following order: 1 Remove the brake disc from the hub. 2 Remove metal shavings from the hub, the brake disc mounting surfaces and from the ABS sensors. 3 Apply anti-seize lubricant to the hub mounting surface to prevent corrosion. 4 Align the match marks and install the brake disc on the hub. 6. NOTE: It is not required to install new brake pads if friction material properties are within guidelines. Install the brake caliper and brake caliper anchor bracket. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5425 Brake Rotor/Disc: Removal and Replacement Disc Removal and Installation, Front Brake Disc - Rear Wheel Drive (RWD) Removal Disc Brake System - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5426 Disc Brake System - Exploded View (Part 2) 1. Remove the wheel and tire. 2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper anchor plate bolts and position the caliper and anchor plate assembly aside. ^ Support the caliper and anchor plate assembly using mechanic's wire. 3. Remove and discard the cotter pin from the spindle nut retainer. 4. Remove the spindle nut retainer and the nut. ^ Discard the spindle nut. 5. Remove the front brake disc from the spindle. Installation 1. Position the brake disc on the spindle. 2. NOTE: Tighten the spindle nut to the specified torque. Rotate the disc counterclockwise 5 rotations and then recheck the torque. Install a new spindle nut. ^ Tighten to 400 Nm (295 lb-ft). 3. Install the spindle nut retainer and a new cotter pin. 4. Position the brake caliper and anchor plate assembly and install 2 new bolts. ^ Tighten to 200 Nm (148 lb-ft). 5. Install the wheel and tire. Disc Removal and Installation, Rear Brake Disc Material Removal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5427 Disc Brake System - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5428 Disc Brake System - Exploded View (Part 2) 1. Remove the wheel and tire. 2. CAUTION: Do not allow the caliper assembly to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper guide pin bolts and position the caliper assembly aside. ^ Support the caliper assembly using mechanic's wire. 3. NOTE: If the brake disc binds on the parking brake shoe and lining, remove the adjustment plug and contract the parking brake shoe and lining. Remove the brake disc. Installation 1. Clean any rust or foreign material from the brake disc and wheel hub. ^ Use brake parts cleaner to clean the brake disc and hub surfaces. 2. CAUTION: Do not allow the lubricant to make contact with the wheel studs, brake pads or brake disc or damage to components may occur. Apply a thin coat of lubricant to the hub flange. 3. Install the brake disc on the wheel hub. 4. Position the brake caliper assembly and install the 2 guide pin bolts. ^ Tighten to 30 Nm (22 lb-ft). 5. Install the wheel and tire. ^ Apply brakes several times to verify correct brake operation. Shield Removal and Installation, Front Brake Disc Shield Removal and Installation Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5429 Disc Brake System - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5430 Disc Brake System - Exploded View (Part 2) 1. Remove the brake disc. 2. Remove the 3 brake disc shield bolts and the brake disc shield. ^ To install, tighten to 12 Nm (9 lb-ft). 3. To install, reverse the removal procedure. Shield Removal and Installation, Rear Brake Disc Shield Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5431 Brake Disc Shield Removal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5432 Disc Brake System - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5433 Disc Brake System - Exploded View (Part 2) 1. Remove the rear axle. 2. Remove the parking brake shoes. 3. Remove the 4 brake caliper support bracket nuts and bolts. ^ To install, tighten to 81 Nm (60 lb-ft). 4. If equipped, drill out the 2 rivets. ^ Protect the seal and bearings from chips. ^ It is not necessary to install new rivets. 5. Separate the brake disc shield from the brake caliper support bracket and the rear axle housing. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding Brake Bleeding: Service and Repair Component Bleeding Component Bleeding Material Master Cylinder WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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. NOTE: When a new brake master cylinder has been installed or the system has been emptied or partially emptied, it should be primed to prevent air from getting into the system. 1. Disconnect the brake master cylinder outlet tubes. 2. NOTE: Original equipment tubes are not intended to be used during this procedure. Install short brake tubes with the ends submerged into the brake master cylinder reservoir and fill the brake master cylinder reservoir with clean, specified brake fluid. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 5439 3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air bubbles. 4. Remove the short brake tubes and install the brake outlet tubes. 5. Bleed each brake tube at the brake master cylinder in the following sequence: 1 Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2 Loosen the rear brake tube fitting until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the brake tube fitting. 3 Repeat this operation until clear, bubble-free fluid comes out. 4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation for the front brake tube. 6. While the assistant maintains pressure on the brake pedal, tighten the brake tube fittings. ^ Tighten to 18 Nm (13 lb-ft). Brake Caliper WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If spilled, wipe up immediately before damage to the painted or plastic surface occurs. 1. Remove the brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the brake caliper bleeder screw to 20 Nm (15 lb ft), remove the rubber hose and install the bleeder screw cap. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 5440 Brake Bleeding: Service and Repair Brake System Bleeding Brake System Bleeding Special Tool(s) Material WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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. NOTE: When the hydraulic control unit (HCU) or master cylinder is disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: Pressure bleed the brake system at 207-345 kPa (30-50 psi). NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. 1. Clean all the dirt from around the brake fluid reservoir cap and remove the cap. Fill the brake master cylinder reservoir with clean, specified brake fluid. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 5441 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough clean, specified brake fluid to complete the bleeding operation. Remove the RH rear brake caliper bleeder cap and place a box end wrench on the bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear brake caliper bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw. ^ Press and release the parking brake 5 times. ^ Repeat until clear, bubble-free fluid comes out. 6. Tighten the RH rear brake caliper bleeder screw to 20 Nm (15 lb-ft), remove the rubber hose and install the bleeder screw cap. 7. Repeat Steps 5 and 6 for the LH rear brake caliper. ^ Tighten the LH rear brake caliper bleeder screw to 20 Nm (15 lb-ft). 8. Continue bleeding the front of the system, going in order from the RH front brake caliper and then to the LH front brake caliper. ^ Tighten the front brake caliper bleeder screws to 20 Nm (15 lb ft). 9. Close the bleeder tank valve. Remove the tank hose from the adapter and remove the adapter. Fill the reservoir with clean, specified brake fluid and install the reservoir cap. Manual Bleeding WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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. NOTE: When the hydraulic control unit (HCU) or master cylinder is disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with clean, specified brake fluid. 2. NOTE: Bleed the brake system from the longest to the shortest brake line. Remove the RH rear brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 5442 4. Loosen the RH rear brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 5. Tighten the RH rear brake caliper bleeder screw to 20 Nm (15 lb-ft), remove the rubber hose and install the bleeder screw cap. 6. Repeat Steps 2 through 5 for the LH rear brake caliper bleeder screw. ^ Tighten the LH rear brake caliper bleeder screw to 20 Nm (15 lb-ft). 7. Remove the RH front brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9. Loosen the RH front brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 10. Tighten the RH front brake caliper bleeder screw to 20 Nm (15 lb-ft), remove the rubber hose and install the bleeder screw cap. 11. Repeat Steps 7 through 10 for the LH front brake caliper bleeder screw. ^ Tighten the LH front brake caliper bleeder screw to 20 Nm (15 lb-ft). ABS Hydraulic Control Unit (HCU) Bleeding WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. 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. NOTE: When the hydraulic control unit (HCU) or master cylinder is disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: This procedure is only required when a new HCU is installed. 1. NOTE: Carrying out the System Bleed function drives trapped air from the HCU. Subsequent bleeding removes the air from the brake hydraulic system through the bleeder screws. NOTE: Adequate voltage to the HCU module is required during the anti-lock control portion of the system bleed. Connect the scan tool to the vehicle. 2. Access the ABS HCU bleed function and follow the directions on the scan tool. 3. Manually bleed the brake hydraulic system. 4. Repeat the procedure carrying out a total of 2 scan tool cycles and 2 manual bleed cycles. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Testing and Inspection > Brake Calipers Brake Caliper: Testing and Inspection Brake Calipers Brake System Inspection Brake Calipers 1. Inspect the brake calipers for leaks, damage to seals and piston corrosion or binding. - If the brake caliper is leaking or otherwise damaged, install a new brake caliper. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Testing and Inspection > Brake Calipers > Page 5447 Brake Caliper: Testing and Inspection Brake Caliper Guide Pins Brake Caliper Guide Pins NOTICE: Do not use power tools for caliper guide pin bore cleaning. Damage to the bore may result. NOTE: The guide pins are part of the anchor plate. The guide pins should slide with a reasonable amount of hand force. If the brake pads show taper wear or the guide pins are difficult to move install a new brake caliper anchor plate. See: Service and Repair If the lining is not within specifications install new brake pads. See: Disc Brake System/Brake Pad/Service and Repair Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front Brake Caliper: Service and Repair Caliper Removal and Installation, Front Brake Caliper Material Removal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 5450 Disc Brake System - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 5451 Disc Brake System - Exploded View (Part 2) WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. 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. 1. Remove the wheel and tire. 2. Remove the brake caliper flow bolt and discard the 2 copper washers. 3. Remove the 2 brake caliper guide pin bolts and the brake caliper. Installation 1. Using 2 new copper washers, position the brake flexible hose on the brake caliper and install the brake caliper flow bolt. ^ Tighten to 35 Nm (26 lb-ft). 2. NOTE: Tighten the lower caliper guide pin bolt first. Position the brake caliper on the brake caliper anchor plate and install the 2 guide pin bolts. ^ Tighten to 74 Nm (55 lb-ft). 3. Bleed the brake caliper. 4. Install the wheel and tire. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 5452 Brake Caliper: Service and Repair Caliper Removal and Installation, Rear Brake Caliper Material Removal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 5453 Disc Brake System - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 5454 Disc Brake System - Exploded View (Part 2) WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. 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. 1. Remove the wheel and tire. 2. Remove the brake caliper flow bolt and discard the 2 copper washers. 3. Remove the 2 guide pin bolts and the brake caliper. Installation 1. Position the brake caliper and install the 2 guide pin bolts. ^ Tighten to 30 Nm (22 lb-ft). 2. Using 2 new copper washers, position the brake hose on the brake caliper and install the flow bolt. ^ Tighten to 35 Nm (26 lb-ft). 3. Bleed the brake caliper. See: Brake Bleeding 4. Install the wheel and tire. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 5455 Brake Caliper: Service and Repair Brake Caliper Anchor Plate, Front Brake Caliper Anchor Plate Material Removal and Installation Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 5456 Disc Brake System - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 5457 Disc Brake System - Exploded View (Part 2) 1. Remove the brake pads. 2. Remove and discard the 2 brake caliper anchor plate bolts. ^ To install, tighten the new bolts to 200 Nm (148 lb-ft). 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID AND CLUTCH FLUID Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid Ford Part Number: .......................... .............................................................................................................................................................. ....... PM-1-C Ford Specification: ......................................................................................................... ......................................................................... WSS-M6C62-A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations View 151-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5464 C124 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front Brake Hose/Line: Service and Repair Front Brake Flexible Hose Material Removal and Installation Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front > Page 5469 Disc Brake System - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front > Page 5470 Disc Brake System - Exploded View (Part 2) WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. 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. 1. Remove the brake caliper flow bolt and discard the 2 copper washers. ^ To install, tighten to 35 Nm (26 lb-ft). 2. Disconnect the brake tube fitting from the brake flexible hose. ^ To install, tighten to 17 Nm (13 lb-ft). 3. Remove the brake flexible hose retaining clip and the brake flexible hose. 4. To install, reverse the removal procedure. ^ Bleed the brake system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front > Page 5471 Brake Hose/Line: Service and Repair Rear Brake Flexible Hose Material Removal and Installation Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front > Page 5472 Disc Brake System - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front > Page 5473 Disc Brake System - Exploded View (Part 2) WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. 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. 1. Remove the wheel and tire. 2. Remove the brake caliper flow bolt and discard the 2 copper washers. ^ To install, tighten to 35 Nm (26 lb-ft). ^ Use new copper washers. 3. Disconnect the brake tube fitting from the brake flexible hose. ^ To install, tighten to 17 Nm (13 lb-ft). 4. Remove the brake hose bracket bolt and the brake hose. ^ To install, tighten to 30 Nm (22 lb-ft). 5. To install, reverse the removal procedure. ^ Bleed the brake caliper. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) Material Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 5477 Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. 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. CAUTION: Electronic modules are sensitive to electrical charges. The anti-lock brake system (ABS) module can be damaged if exposed to these charges. CAUTION: When installing a new anti-lock brake system (ABS) module or hydraulic control unit (HCU), do not use the pump motor harness as a carrying handle. Failure to follow these instructions may result in damage to the HCU assembly. CAUTION: When disconnecting the brake tubes, do not allow brake fluid to drip onto the anti-lock brake system (ABS) module or premature failure may occur. CAUTION: Do not allow brake fluid to drip into the anti-lock brake system (ABS) module electrical connector cavity or premature failure may occur. All vehicles 1. Disconnect the battery ground cable. For additional information, refer to Battery. Vehicles equipped with 5.4L engine 2. Remove the air cleaner intake pipe. For additional information, refer to Fuel Delivery and Air Induction. Vehicles equipped with 4.6L and 4.2L engine 3. Remove the air cleaner assembly. For additional information, refer to Fuel Delivery and Air Induction. All vehicles 4. NOTE: The brake tubes must be installed in the same location as removed. Remove the 5 brake tube-to-hydraulic control unit (HCU) fittings. ^ To install, tighten to 22 Nm (16 lb-ft). 5. Remove the 2 HCU-to-bracket nuts and the HCU. ^ To install, tighten to 8 Nm (71 lb-in). 6. Remove the ABS module. 7. NOTE: The HCU bracket does not have to be removed in order to complete this procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 5478 If necessary, remove the 3 HCU-bracket-to-frame bolts and the bracket. ^ To install, tighten to 30 Nm (22 lb-ft). 8. To install, reverse the removal procedure. ^ Bleed the brake system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition Brake Master Cylinder: Testing and Inspection Brake Master Cylinder - Bypass Condition Brake Master Cylinder - Bypass Condition 1. Disconnect the brake tubes from the master cylinder. 2. Plug the outlet ports of the master cylinder. 3. Apply the brakes. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and a new brake master cylinder must be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition > Page 5483 Brake Master Cylinder: Testing and Inspection Brake Master Cylinder - Compensator Port Brake Master Cylinder - Compensator Port The purpose of the compensator ports in the brake master cylinder is to: ^ supply additional brake fluid from the brake master cylinder reservoir needed by the brake system due to brake lining wear. ^ allow brake fluid to return to the brake master cylinder reservoir when the brakes are released. The returning brake fluid creates a slight turbulence in the brake master cylinder reservoir. This is a normal condition and indicates that the compensator ports are not clogged. Clogged compensator ports may cause the brakes to hang up or not fully release. If clogged compensator ports are suspected, proceed as follows: 1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Maintenance/Service and Repair. 2. With the brakes released, attempt to rotate each wheel and check for any brake drag. ^ If an excessive amount of brake drag exists at all 4 wheels, continue with the test. ^ If an excessive amount of brake drag exists at only one wheel, it indicates a possible seized brake caliper, brake wheel cylinder or parking brake component. Repair or install new components as necessary. 3. Check the brake stop lamp switch and the brake pedal free play to verify that the brake pedal is not partially applied. 4. Loosen the brake master cylinder nuts and position the brake master cylinder away from the brake booster. 5. With the brakes released, attempt to rotate each wheel and check for any brake drag. ^ If the brake drag is no longer present, install a new brake booster. ^ If the brake drag is still present, install a new master cylinder. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation Brake Master Cylinder: Service and Repair Removal and Installation Brake Master Cylinder Material Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. 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. 1. Using a suitable suction device, drain the brake fluid reservoir. 2. Disconnect the brake fluid level switch electrical connector. 3. NOTE: Cap the brake tubes and plug the master cylinder ports. Disconnect the 2 brake tubes from the master cylinder. ^ To install, tighten to 17 Nm (13 lb-ft). 4. Remove the 2 master cylinder nuts. ^ To install, tighten to 25 Nm (18 lb-ft). 5. To install, reverse the removal procedure. ^ Bleed the brake system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 5486 Brake Master Cylinder: Service and Repair Brake Fluid Reservoir Brake Fluid Reservoir Material Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. 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. 1. Using a suitable suction device, drain the brake fluid reservoir. 2. Disconnect the brake fluid level switch electrical connector. 3. Remove the 2 spiral pins from the master cylinder and the brake fluid reservoir. 4. Separate the brake fluid reservoir from the master cylinder. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Cable: > 08-11-1 > Jun > 08 > Brakes Vibration At 45 MPH/Park Brake Partial Release Parking Brake Cable: Customer Interest Brakes - Vibration At 45 MPH/Park Brake Partial Release TSB 08-11-1 06/09/08 INTERMITTENT VEHICLE VIBRATION - PARKING BRAKE DISENGAGEMENT CONCERNS FORD: 2004-2008 F-150, F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 08-4-18 to update the Part List. ISSUE Some 2004-2008 F-i 50 (excludes Heritage) and 2006-2008 Mark LT vehicles may exhibit an intermittent vibration or shudder from the rear of the vehicle typically at speeds 45 MPH (72 Km/h) and higher. This may be caused by the parking brake remaining partially engaged. Affected vehicles were produced at: Dearborn Truck Plant before 2/13/2008, Kansas City Assembly Plant before 2/18/2008 and all 2004-2007 vehicles produced at Norfolk Assembly Plant. ACTION Inspect the parking brake assembly for evidence of remaining partially engaged and repair using the following service procedure. SERVICE PROCEDURE 1. Raise the vehicle and remove the right hand (RH) and left hand (LH) rear brake rotors. Refer to Workshop Manual (WSM), Sections 206-00 for 2004 and 206-04 for 2005-2008. 2. Inspect the parking brake shoes and parking brake drum for signs of engagement while driving (excessive discoloring and wear). If the parking brake system does not indicate signs of trouble, this is not the cause of the vibration. Do not continue with this TSB. Refer to the appropriate WSM, Section 100-04 for NVH diagnosis. 2004-2005 Model Year Vehicles 1. Replace both the RH and LH parking brake actuator levers and replace the parking brake cable assembly on the affected side of the vehicle only. Refer to WSM, Section 206-00 for 2004, Section 206-05 for 2005. Refer to parts list to determine the correct cable assembly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Cable: > 08-11-1 > Jun > 08 > Brakes Vibration At 45 MPH/Park Brake Partial Release > Page 5496 2. Correctly position the parking brake cable equalizer to ensure the LH and RH parking brake cables do not twist or bind during operation. (Figure 1 - LH side) 3. Inspect the double cable clamp for debris and/or damage. Replace as required. 4. Use a shop towel to clean the sheathing on both parking brake cables where the double cable clamp will be positioned. (Figure 2 - LH side) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Cable: > 08-11-1 > Jun > 08 > Brakes Vibration At 45 MPH/Park Brake Partial Release > Page 5497 5. Spray an even coat of Motorcraft® Silicone Spray Lubricant or equivalent, on the sheathing of both parking brake cables where the double cable clamp will be positioned. (Figure 2) NOTE CORRECT PARKING BRAKE SHOE ADJUSTMENT DIMENSION IS 0.027" (0.71 mm). 2006-2008 Model Year Vehicles 1. Replace the parking brake cable assembly on the affected side of the vehicle only. Refer to WSM, section 206-05. 2. Correctly position the parking brake cable equalizer to ensure the LH and RH parking brake cables do not twist or bind during operation. (Figure 1) 3. Inspect the double cable clamp for debris and/or damage. Replace as required. 4. Use a shop towel to clean the sheathing on both parking brake cables where the double cable clamp will be positioned. (Figure 2) 5. Spray an even coat of silicone spray, Motorcraft® Silicone Spray Lubricant or equivalent, on the sheathing of both parking brake cables where the double cable clamp will be positioned. (Figure 2) NOTE CORRECT PARKING BRAKE SHOE ADJUSTMENT DIMENSION IS 0.027" (0.71 mm). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Cable: > 08-11-1 > Jun > 08 > Brakes Vibration At 45 MPH/Park Brake Partial Release > Page 5498 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081101A 2004-2005 F-150: Replace 1.4 Hrs. Both Parking Brake Actuators, And One Parking Brake Cable Assembly, Includes Time For Inspection, Cleaning And Lubricating (Do Not Use With 2635A, 2001B, 2001B5, 2001B10) 081101B 2004-2005 F-150: Replace 1.5 Hrs. Both Parking Brake Actuators, And Both Parking Brake Cable Assemblies, Includes Time For Inspections, Cleaning And Lubricating (Do Not Use With 2635A, 2001B, 2001B5, 2001B10) 081101C 2006-2008 F-150/Mark LT: 1.1 Hrs. Replace One Parking Brake Cable Assembly, Includes Time For Inspection, Cleaning And Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Cable: > 08-11-1 > Jun > 08 > Brakes Vibration At 45 MPH/Park Brake Partial Release > Page 5499 Lubricating (Do Not Use With 2635A, 2001B, 2001B5, 2001B10) 081101D 2006-2008 F-150/Mark LT: 1.2 Hrs. Replace Both Parking Brake Cable Assemblies, Includes Time For Inspection, Cleaning And Lubricating (Do Not Use With 2635A, 2001B, 2001B5, 2001B10) DEALER CODING CONDITION BASIC PART NO. CODE 2A635 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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: > 08-11-1 > Jun > 08 > Brakes - Vibration At 45 MPH/Park Brake Partial Release Parking Brake Cable: All Technical Service Bulletins Brakes - Vibration At 45 MPH/Park Brake Partial Release TSB 08-11-1 06/09/08 INTERMITTENT VEHICLE VIBRATION - PARKING BRAKE DISENGAGEMENT CONCERNS FORD: 2004-2008 F-150, F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 08-4-18 to update the Part List. ISSUE Some 2004-2008 F-i 50 (excludes Heritage) and 2006-2008 Mark LT vehicles may exhibit an intermittent vibration or shudder from the rear of the vehicle typically at speeds 45 MPH (72 Km/h) and higher. This may be caused by the parking brake remaining partially engaged. Affected vehicles were produced at: Dearborn Truck Plant before 2/13/2008, Kansas City Assembly Plant before 2/18/2008 and all 2004-2007 vehicles produced at Norfolk Assembly Plant. ACTION Inspect the parking brake assembly for evidence of remaining partially engaged and repair using the following service procedure. SERVICE PROCEDURE 1. Raise the vehicle and remove the right hand (RH) and left hand (LH) rear brake rotors. Refer to Workshop Manual (WSM), Sections 206-00 for 2004 and 206-04 for 2005-2008. 2. Inspect the parking brake shoes and parking brake drum for signs of engagement while driving (excessive discoloring and wear). If the parking brake system does not indicate signs of trouble, this is not the cause of the vibration. Do not continue with this TSB. Refer to the appropriate WSM, Section 100-04 for NVH diagnosis. 2004-2005 Model Year Vehicles 1. Replace both the RH and LH parking brake actuator levers and replace the parking brake cable assembly on the affected side of the vehicle only. Refer to WSM, Section 206-00 for 2004, Section 206-05 for 2005. Refer to parts list to determine the correct cable assembly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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: > 08-11-1 > Jun > 08 > Brakes - Vibration At 45 MPH/Park Brake Partial Release > Page 5505 2. Correctly position the parking brake cable equalizer to ensure the LH and RH parking brake cables do not twist or bind during operation. (Figure 1 - LH side) 3. Inspect the double cable clamp for debris and/or damage. Replace as required. 4. Use a shop towel to clean the sheathing on both parking brake cables where the double cable clamp will be positioned. (Figure 2 - LH side) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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: > 08-11-1 > Jun > 08 > Brakes - Vibration At 45 MPH/Park Brake Partial Release > Page 5506 5. Spray an even coat of Motorcraft® Silicone Spray Lubricant or equivalent, on the sheathing of both parking brake cables where the double cable clamp will be positioned. (Figure 2) NOTE CORRECT PARKING BRAKE SHOE ADJUSTMENT DIMENSION IS 0.027" (0.71 mm). 2006-2008 Model Year Vehicles 1. Replace the parking brake cable assembly on the affected side of the vehicle only. Refer to WSM, section 206-05. 2. Correctly position the parking brake cable equalizer to ensure the LH and RH parking brake cables do not twist or bind during operation. (Figure 1) 3. Inspect the double cable clamp for debris and/or damage. Replace as required. 4. Use a shop towel to clean the sheathing on both parking brake cables where the double cable clamp will be positioned. (Figure 2) 5. Spray an even coat of silicone spray, Motorcraft® Silicone Spray Lubricant or equivalent, on the sheathing of both parking brake cables where the double cable clamp will be positioned. (Figure 2) NOTE CORRECT PARKING BRAKE SHOE ADJUSTMENT DIMENSION IS 0.027" (0.71 mm). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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: > 08-11-1 > Jun > 08 > Brakes - Vibration At 45 MPH/Park Brake Partial Release > Page 5507 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081101A 2004-2005 F-150: Replace 1.4 Hrs. Both Parking Brake Actuators, And One Parking Brake Cable Assembly, Includes Time For Inspection, Cleaning And Lubricating (Do Not Use With 2635A, 2001B, 2001B5, 2001B10) 081101B 2004-2005 F-150: Replace 1.5 Hrs. Both Parking Brake Actuators, And Both Parking Brake Cable Assemblies, Includes Time For Inspections, Cleaning And Lubricating (Do Not Use With 2635A, 2001B, 2001B5, 2001B10) 081101C 2006-2008 F-150/Mark LT: 1.1 Hrs. Replace One Parking Brake Cable Assembly, Includes Time For Inspection, Cleaning And Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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: > 08-11-1 > Jun > 08 > Brakes - Vibration At 45 MPH/Park Brake Partial Release > Page 5508 Lubricating (Do Not Use With 2635A, 2001B, 2001B5, 2001B10) 081101D 2006-2008 F-150/Mark LT: 1.2 Hrs. Replace Both Parking Brake Cable Assemblies, Includes Time For Inspection, Cleaning And Lubricating (Do Not Use With 2635A, 2001B, 2001B5, 2001B10) DEALER CODING CONDITION BASIC PART NO. CODE 2A635 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures Parking Brake Cable: Procedures Parking Brake Cable Tension Release Parking Brake - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 5511 Parking Brake - Exploded View (Part 2) Parking Brake Cable-Front 1. Release the parking brake. 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. With an assistant, release the parking brake cable tension by pulling down on the intermediate cable at the cable-to-cable union until the parking brake control sector rotates to its stop and a 4 mm (0.15 inch) x 15 0 mm (5.9 inch) retainer pin can be inserted. 4. Disconnect the cable at the cable-to-cable union. 5. To reload the tension on the parking brake cable, follow the release procedure in reverse. ^ Inspect the parking brake system for correct operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 5512 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 5513 Parking Brake Cable: Removal and Replacement Parking Brake Cable - Rear, LH Parking Brake Cable - Rear, LH Removal and Installation Parking Brake - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 5514 Parking Brake - Exploded View (Part 2) 1. Relieve the parking brake cable tension. 2. Release the intermediate cable from the LH rear cable from the cable equalizer. 3. Release the front of the LH rear cable conduit at the frame bracket. 4. Remove and discard the double cable clamp. 5. Disconnect the LH rear parking brake cable from the rear parking brake levers and remove the cable from the vehicle. 6. To install, reverse the removal procedure. ^ Inspect the parking brake system for correct operation. Parking Brake Cable - Rear, RH Parking Brake Cable - Rear, RH Removal and Installation Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 5515 Parking Brake - Exploded View (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 5516 Parking Brake - Exploded View (Part 2) 1. Relieve the parking brake cable tension. 2. Release the intermediate cable from the LH rear cable from the cable equalizer. 3. Remove and discard the double cable clamp. 4. Remove the RH parking brake bracket bolt. ^ To install, tighten to 30 Nm (22 lb-ft). 5. Disconnect the RH rear parking brake cable from the rear parking brake levers and remove the cable from the vehicle. 6. To install, reverse the removal procedure. ^ Inspect the parking brake system for correct operation. Parking Brake Cable - Front Parking Brake Cable - Front Removal and Installation Parking Brake Cable-Front 1. Release the tension on the parking brake cable. 2. Remove the LH cowl side trim panel. For additional information, refer to Trim Panel. 3. NOTE: The parking brake control take-up spool tab may need to be bent aside to allow the cable to be removed. Disconnect the front parking brake cables from the parking brake control. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 5517 4. Release the front parking brake cable conduit from the parking brake control. 5. Detach the cable conduit seal and remove the cable. 6. To install, reverse the removal procedure. ^ Inspect the parking brake system for correct operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Service and Repair Parking Brake Control: Service and Repair Parking Brake Control Parking Brake Control Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the LH cowl side trim panel. For additional information, refer to Trim Panel. 3. Release the tension on the parking brake cable. 4. Remove the parking brake release handle bolt and pull the handle assembly down to prevent breaking off the locator tabs. 5. Disconnect the parking brake release handle cable from the parking brake control. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Service and Repair > Page 5521 6. Disconnect the parking brake switch electrical connector. 7. Remove the 3 bolts from the parking brake control. ^ To install, tighten to 20 Nm (15 lb-ft). 8. Position the cable conduit grommet up through the floor. ^ Release the cable from the parking brake control. 9. Remove the parking brake control from the vehicle. 10. To install, reverse the removal procedure. ^ Inspect the parking brake system for correct operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments Parking Brake Shoe: Adjustments Parking Brake Shoe Adjustment 1. NOTE: Make sure the parking brake is fully released. Using the release handle, release the parking brake control. 2. Remove the rear brake disc. 3. Using the Brake Adjusting Gauge, measure the ID of the drum portion of the rear brake disc and set the locking screw. - Record the measurement. 4. Place the Brake Adjusting Gauge over the widest diameter of the parking brake shoes. 5. Adjust the parking brake shoe clearance to 0.71 mm (0.027 in) less than the ID of the drum portion of the rear brake disc. - Rotate the parking brake shoe adjuster to achieve the correct parking brake shoe-to-brake disc clearance. 6. Install the rear brake disc. 7. Test the parking brake for normal operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 5525 Parking Brake Shoe: Service and Repair Parking Brake Shoes Material Drum Brake System (1 Of 2) Drum Brake System (2 Of 2) Removal NOTE: One parking brake shoe kit contains the linings required for both the LH and RH side. 1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake cable. 2. Remove the rear brake disc. 3. Remove the brake shoe adjuster screw. 4. Remove the brake shoe adjuster screw spring. 5. Remove the 2 brake shoe hold-down springs and 2 pins. 6. Remove the brake shoe retracting spring and the parking brake shoes. Installation 1. NOTE: Lubricate the parking brake shoes where the shoe contacts the wear pad on the backing plate. Position the parking brake shoes and attach the retracting spring. 2. Install the 2 brake shoe hold-down pins and springs. 3. Install the brake shoe adjusting screw spring. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 5526 4. NOTE: Completely retract the parking brake adjusting screw before installation. Install the brake shoe adjusting screw. 5. Use the special tool to measure the inside diameter of the parking brake drum. 6. Adjust the parking brake shoe. 7. Reload the tension on the parking brake cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5530 C2015 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5531 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the parking brake warning indicator switch electrical connector. 3. Remove the parking brake warning indicator switch screw and the switch. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Torque Specifications Torque Specifications (Part 1) Torque Specifications (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5536 Vacuum Brake Booster: Description and Operation Brake Booster The power brake actuation system consists of the following components: ^ Brake booster assembly ^ Brake booster vacuum fitting The brake booster uses engine vacuum from the intake manifold to create a partial vacuum inside the vacuum booster on both sides of the diaphragm. When the brake pedal is pressed, the booster rod opens a valve, allowing air to enter the booster on one side of the diaphragm while sealing off the opposite side. This increases pressure on that side of the diaphragm so that it helps push the rod, which in turn pushes the piston in the master cylinder. As the brake pedal is released, the valve seals off the outside air supply while opening the vacuum valve. This restores vacuum to both sides of the diaphragm, allowing everything to return to its original position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5537 Vacuum Brake Booster: Testing and Inspection Brake Booster 1. Disconnect the check valve from the brake booster. 2. Apply the parking brake, start the engine and place the transmission in NEUTRAL. 3. Verify that manifold vacuum is available at the check valve with the engine at idle speed and the transmission in NEUTRAL. ^ If manifold vacuum is available, stop the engine, connect the check valve and continue with Step 5. ^ If manifold vacuum is not available, continue with Step 4. 4. Disconnect the check valve from the vacuum hose and verify that manifold vacuum is available at the hose with the engine at idle speed and the transmission in NEUTRAL. ^ If manifold vacuum is available, stop the engine, install a new check valve and continue with Step 5. ^ If manifold vacuum is not available, stop the engine, connect the vacuum hose to the check valve and diagnose the no vacuum condition. 5. Apply the brake pedal several times to exhaust all vacuum from the system. 6. Apply the brake pedal and hold it in the applied position. Start the engine and verify that the brake pedal moves downward after the engine starts. ^ If the brake pedal moves, the brake booster is operating correctly. ^ If the brake pedal does not move, install a new brake booster. 7. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the vehicle stand for 10 minutes. Then apply the brake pedal with approximately 89 N (20 lb) of force. The brake pedal feel should be the same as that noted with the engine operating. If the brake pedal feels hard (no power assist), install a new brake booster check valve and retest. If the brake pedal feels spongy, bleed the hydraulic system to remove air. Refer to Brake System Bleeding. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5538 Vacuum Brake Booster: Service and Repair Brake Booster Removal and Installation Brake Booster (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5539 Brake Booster (Part 2) 1. Disconnect the brake fluid level warning switch electrical connector. 2. CAUTION: For vehicles with 4.6L engines, brake booster vacuum hose is routed over the top of the exhaust gas recirculation (EGR) valve; do not route it under the valve or damage to the hose may occur. Disconnect the brake booster vacuum hose from the brake booster vacuum fitting. 3. Remove the 2 brake master cylinder nuts and position the master cylinder aside. ^ To install, tighten to 25 Nm (18 lb-ft). 4. CAUTION: Do not service the brake pedal or brake booster without first removing the stop lamp switch and speed control deactivator switch. These switches must be removed with the brake pedal in the at-rest position. Switch plungers must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) will result in damage to the switch. Remove the speed control deactivator switch. For additional information, refer to Cruise Control. 5. Remove the redundant self-locking pin cover and the self-locking pin. 6. Position the stop lamp switch, booster rod and bushing away from the brake pedal pin. 7. Remove the 4 brake booster nuts. ^ To install, tighten to 25 Nm (18 lb-ft). 8. CAUTION: Do not press, pull or otherwise move the brake pedal while installing the stop lamp switch or the speed control deactivator switch. These switches must be installed with the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position. Installing these switches with the brake pedal in any other position will result in incorrect adjustment and may damage the switches. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Testing and Inspection Vacuum Brake Booster Check Valve: Testing and Inspection Check Valve The function of the brake booster check valve is to allow manifold vacuum to enter the brake booster and prevent the escape of vacuum in case manifold vacuum is lost during sustained full throttle operation. 1. Disconnect the vacuum booster hose from the check valve. 2. Apply the parking brake, start the engine and place the transmission in NEUTRAL. 3. Verify that manifold vacuum is available at the check valve end of the vacuum hose with the engine at idle speed and the transmission in NEUTRAL. ^ If manifold vacuum is available, stop the engine, connect the vacuum hose to the check valve and continue this test. ^ If manifold vacuum is not available, stop the engine, connect the vacuum hose to the check valve and diagnose the no vacuum condition. 4. Connect the vacuum hose to the check valve and run the engine for at least 10 seconds. 5. Operate the brake pedal to check for power assist. ^ If power assist is present, continue with this test. ^ If power assist is not present, refer to Brake Booster Component Test. See: Testing and Inspection/Component Tests and General Diagnostics/Brake Booster 6. NOTE: Do not remove the brake booster check valve from the brake booster in this step. Stop the engine and disconnect the vacuum booster hose from the brake booster check valve. 7. Apply the brake and verify that there is enough vacuum retained in the brake booster for at least one power assisted brake application. ^ If there is enough vacuum for at least one power assisted brake application, the check valve is functioning correctly. ^ If there is not enough vacuum for at least one power-assisted brake application, continue with this test. 8. Inspect the brake booster for any signs of damage that could cause a leak. ^ If any damage is found, install a new brake booster and repeat this test. ^ If no damage is found, install a new check valve. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Locations View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations View 151-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5551 C135 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5552 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Anti-Lock Brake System (ABS) Module Removal and Installation CAUTION: Electronic modules are sensitive to electrical charges. The anti-lock brake system (ABS) module can be damaged if exposed to these charges. CAUTION: When installing a new anti-lock brake system (ABS) module or hydraulic control unit (HCU), do not use the pump motor harness as a carrying handle. Failure to follow these instructions may result in damage to the HCU assembly. All vehicles 1. Disconnect the battery ground cable. For additional information, refer to Battery. Vehicles equipped with 5.4L engine 2. Remove the air cleaner intake pipe. For additional information, refer to Fuel Delivery and Air Induction. All vehicles 3. Disconnect the ABS module electrical connector. 4. Remove the 4 screws and the ABS module. ^ To install, tighten to 3 Nm (27 lb-in). 5. NOTE: The ABS module is not repairable. If an internal problem exists, a new part must be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5553 To install, reverse the removal procedure. When installing a new ABS module, it must be configured (using vehicle as-built data) and calibrated. Follow the scan tool directions for calibration procedures. For additional information on configuration, refer to Information Bus (Module Configuration). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations View 151-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5561 C124 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations > Page 5565 C455 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5569 C2015 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5570 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the parking brake warning indicator switch electrical connector. 3. Remove the parking brake warning indicator switch screw and the switch. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations View 151-14 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 5574 C280 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front View 151-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 5579 View 151-2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front C150 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 5582 C160 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor - Front, Rear Wheel Drive (RWD) Wheel Speed Sensor - Front, Rear Wheel Drive (RWD) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. NOTE: The harness connector is located in the engine compartment secured to the fender apron. Disconnect the wheel speed sensor electrical connector. 3. Disconnect the 2 wheel speed sensor harness retainers from the brake hose. 4. Remove the wheel speed sensor harness from the pushpin retainer. 5. Remove the bolt and the wheel speed sensor. ^ To install, tighten to 8 Nm (71 lb-in). 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5585 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Disconnect the wheel speed sensor electrical connector. 3. Remove the wheel speed sensor bolt. ^ To install, tighten to 15 Nm (11 lb-ft). 4. NOTE: Install a new O-ring before installing the rear axle speed sensor. Remove the wheel speed sensor. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 5591 C257 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Part 1 Part 2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Page 5596 Removal and Installation NOTE: - When a new lock cylinder is installed, the tailgate lock cylinder, door lock cylinders and the ignition lock cylinder should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is to be used, the new key code is attached to a tag. - The individual door lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build a new lock cylinder to the current key code of the vehicle. 1. Remove the steering wheel. 2. Remove bolt and the lower steering column shroud. 3. NOTE: The steering column shift is shown, the floor console shift is similar. Position the ignition lock cylinder cover aside. 4. Disconnect the PATS transceiver electrical connector. 5. Remove the screw and the PATS transceiver. 6. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove the lock cylinder. 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 5600 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 5601 C167 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5606 Starter Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5607 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair Battery Cable: Service and Repair BATTERY CABLES Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 5612 Part 2 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery. 3. Remove the nut and position the starter solenoid positive cable terminal aside. - To install, tighten to 12 Nm (9 lb-ft). 4. Remove the nut and position the starter solenoid wire terminal aside. - To install, tighten to 5 Nm (44 lb-in). 5. Remove the nut and position the starter motor ground cable terminal aside. - To install, tighten to 22 Nm (16 lb-ft). 6. Disconnect the battery cable harness locator on the RH engine mount. 7. Remove the nut and position the battery cable lower bracket aside. - To install, tighten to 10 Nm (89 lb-in). 8. Remove the bolt and position the battery ground cable frame terminal aside. - To install, tighten to 30 Nm (22 lb-ft). 9. Disconnect the battery cable harness locator from the radiator fan shroud. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 5613 10. Remove the nut and position the generator harness terminal and the central junction box (CJB) cable terminal (on the positive battery terminal) aside. To install, tighten to 9 Nm (80 lb-in). 11. Remove the bolt and position the battery ground cable body terminal aside. - To install, tighten to 12 Nm (9 lb-ft). 12. Disconnect the battery cable harness in-line electrical connector and remove the battery cable assembly. 13. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Alternator: Electrical Specifications Item....................................................................................................................................................... ..............................................................Specification Generator amps.............................................................................65/110 amp (max) (R) 1,800-6,000 generator rpm, approximately 525-2,000 engine rpm Voltage......................................... .............................................................................................................................................................. ..................12 volts Generator Load at 2,000 rpm................................................................................................................................ ....................................................................65 amps No Load at 2,000 rpm........................................ .......................................................................................................................between 13.2 and 15.5 volts Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 5619 Torque Specifications Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5622 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5623 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5624 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5625 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5626 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5627 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5628 Alternator: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5629 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5630 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5631 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5632 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5633 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5634 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5635 Alternator: Connector Views C102A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5636 C102B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 5637 Alternator: Application and ID Item....................................................................................................................................................... ..............................................................Specification Generator Generator pulley ratio........................................................................................................................... ..........................................................................2.96:1 Rating............................................................................................65/110 amp (max) (R) 1,800-6,000 generator rpm, approximately 525-2,000 engine rpm Voltage regulator type...................................... ....................................................................................................................Electronic internal with generator Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 5638 Alternator: Description and Operation GENERATOR The charging system consists of the following components: - Generator - Integral voltage regulator The generator is belt-driven by the engine accessory drive system. The generator has an internal voltage regulator that is not replaced separately. The generator and voltage regulator are repaired as an assembly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 5639 Alternator: Service and Repair GENERATOR Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 5640 Part 2 Removal and Installation NOTE: 5.4L shown, 4.6L similar. 1. Disconnect the battery. 2. If equipped with the 4.6L engine, remove the air cleaner outlet pipe. 3. If equipped with the 5.4L engine, remove the air cleaner inlet pipe. 4. Rotate the front end accessory drive (FEAD) belt tensioner clockwise and position the FEAD belt aside. 5. Release the generator harness locator from the generator bracket. 6. Remove the 4 bolts and the generator bracket. - To install, tighten to 10 Nm (89 lb-in). 7. Loosen the 2 generator bolts and position the generator aside to access the electrical connections. - To install, tighten to 25 Nm (18 lb-ft). 8. Disconnect the generator electrical connector. 9. Position the generator B+ protective boot aside and remove the generator B+ nut and terminal, and remove the generator. - To install, tighten to 8 Nm (71 lb-in). 10. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 5645 C257 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Part 1 Part 2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Page 5650 Removal and Installation NOTE: - When a new lock cylinder is installed, the tailgate lock cylinder, door lock cylinders and the ignition lock cylinder should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is to be used, the new key code is attached to a tag. - The individual door lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build a new lock cylinder to the current key code of the vehicle. 1. Remove the steering wheel. 2. Remove bolt and the lower steering column shroud. 3. NOTE: The steering column shift is shown, the floor console shift is similar. Position the ignition lock cylinder cover aside. 4. Disconnect the PATS transceiver electrical connector. 5. Remove the screw and the PATS transceiver. 6. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove the lock cylinder. 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 5654 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 5655 C167 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Testing and Inspection Starter Drive/Bendix: Testing and Inspection STARTER MOTOR DRIVE GEAR AND FLYWHEEL RING GEAR INSPECTION 1. Check the wear patterns on the starter drive and the flywheel ring gear. If the wear pattern is not normal, install a new starter motor. 2. If the starter drive gear and the flywheel ring gear are not fully meshing or the gears are milled or damaged, install a new starter motor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5663 Starter Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5664 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Instrument Panel C2033 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Instrument Panel > Page 5670 C3063 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Instrument Panel > Page 5671 C3064 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Instrument Panel > Page 5672 C9036 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5673 Auxiliary Power Outlet: Service and Repair POWER POINT Special Tool(s) Special Tool(s) Removal NOTE: Power point cover may differ depending on location. 1. Open the power point cover. 2. Install the special tool in one of the power point socket slots. 3. Position the special tool so that it engages in the adjacent slot. 4. Using the special tool, pull the power point socket out of the retainer. 5. Disconnect the electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5674 Installation 1. Connect the electrical connector. 2. Slide the power point socket into the retainer. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor #1 Electronic Noise Suppressor: Diagrams Ignition Transformer Capacitor #1 C174 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor #1 > Page 5679 C1544 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor #1 > Page 5680 Electronic Noise Suppressor: Diagrams Ignition Transformer Capacitor #2 C194 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor #1 > Page 5681 C1545 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor #1 > Page 5682 C1196 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse: Locations Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5687 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5688 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5689 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5690 Fuse: Locations Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5693 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5694 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5695 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5696 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5697 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5698 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5699 Fuse: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5700 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5701 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5702 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5703 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5704 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5705 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5708 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5709 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5710 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5711 Fuse: Application and ID Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5716 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5717 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5718 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5719 Fuse Block: Locations Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5722 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5723 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5724 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5725 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5726 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5727 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5728 Fuse Block: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5729 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5730 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5731 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5732 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5733 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5734 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5735 Fuse Block: Connector Views C270A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5736 C270B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5737 C270C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5738 C270D Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5739 C270E Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5740 C270F C270G Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5741 C270H Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5742 C270J Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5743 C270K Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5744 C270M Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5745 C270N C270P Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5748 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5749 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5750 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5751 Fuse Block: Application and ID Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 5758 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 Multiple Junction Connector: Diagrams C110-C327 C110 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5763 C133 C134 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5764 C139 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5765 C140 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5766 C144 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5767 C145 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5768 C211 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5769 C212 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5770 C213 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5771 C214 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5772 C219 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5773 C238 (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5774 C238 (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5775 C248 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5776 C298 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5777 C299 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5778 C312 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5779 C313 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5780 C314 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5781 C315 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5782 C316 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5783 C327 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5784 Multiple Junction Connector: Diagrams C339-C3206 C339 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5785 C340 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5786 C405 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5787 C406 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5788 C408 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5789 C410 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5790 C411 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5791 C431 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5792 C1033 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5793 C2026 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5794 C2095 (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5795 C2095 (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5796 C2108 (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5797 C2108 (Part 2) C3007 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5798 C3050 C3051 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5799 C3133 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5800 C3134 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5801 C3135 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5802 C3136 (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5803 C3136 (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5804 C3138 C3205 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5805 C3206 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 5816 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5824 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5825 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5826 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5827 Relay Box: Locations Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5828 Relay Box: Diagrams C270A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5829 C270B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5830 C270C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5831 C270D Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5832 C270E Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5833 C270F C270G Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5834 C270H Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5835 C270J Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5836 C270K Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5837 C270M Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5838 C270N C270P Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5841 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5842 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5843 Relay Box: Application and ID Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5844 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5849 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5850 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5851 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5852 Relay Box: Locations Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5853 Relay Box: Diagrams C270A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5854 C270B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5855 C270C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5856 C270D Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5857 C270E Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5858 C270F C270G Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5859 C270H Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5860 C270J Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5861 C270K Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5862 C270M Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5863 C270N C270P Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5866 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5867 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5868 Relay Box: Application and ID Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5869 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Instrument Panel C2033 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Instrument Panel > Page 5875 C3063 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Instrument Panel > Page 5876 C3064 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Instrument Panel > Page 5877 C9036 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5878 Auxiliary Power Outlet: Service and Repair POWER POINT Special Tool(s) Special Tool(s) Removal NOTE: Power point cover may differ depending on location. 1. Open the power point cover. 2. Install the special tool in one of the power point socket slots. 3. Position the special tool so that it engages in the adjacent slot. 4. Using the special tool, pull the power point socket out of the retainer. 5. Disconnect the electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5879 Installation 1. Connect the electrical connector. 2. Slide the power point socket into the retainer. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor #1 Electronic Noise Suppressor: Diagrams Ignition Transformer Capacitor #1 C174 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor #1 > Page 5884 C1544 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor #1 > Page 5885 Electronic Noise Suppressor: Diagrams Ignition Transformer Capacitor #2 C194 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor #1 > Page 5886 C1545 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor #1 > Page 5887 C1196 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse: Locations Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5892 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5893 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5894 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5895 Fuse: Locations Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5898 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5899 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5900 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5901 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5902 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5903 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5904 Fuse: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5905 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5906 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5907 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5908 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5909 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5910 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5913 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5914 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5915 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5916 Fuse: Application and ID Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5921 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5922 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5923 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5924 Fuse Block: Locations Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5927 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5928 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5929 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5930 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5931 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5932 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5933 Fuse Block: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5934 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5935 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5936 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5937 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5938 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5939 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5940 Fuse Block: Connector Views C270A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5941 C270B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5942 C270C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5943 C270D Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5944 C270E Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5945 C270F C270G Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5946 C270H Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5947 C270J Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5948 C270K Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5949 C270M Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5950 C270N C270P Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5953 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5954 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5955 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 5956 Fuse Block: Application and ID Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 5963 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 Multiple Junction Connector: Diagrams C110-C327 C110 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5968 C133 C134 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5969 C139 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5970 C140 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5971 C144 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5972 C145 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5973 C211 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5974 C212 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5975 C213 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5976 C214 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5977 C219 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5978 C238 (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5979 C238 (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5980 C248 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5981 C298 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5982 C299 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5983 C312 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5984 C313 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5985 C314 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5986 C315 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5987 C316 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5988 C327 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5989 Multiple Junction Connector: Diagrams C339-C3206 C339 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5990 C340 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5991 C405 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5992 C406 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5993 C408 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5994 C410 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5995 C411 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5996 C431 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5997 C1033 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5998 C2026 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 5999 C2095 (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 6000 C2095 (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 6001 C2108 (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 6002 C2108 (Part 2) C3007 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 6003 C3050 C3051 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 6004 C3133 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 6005 C3134 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 6006 C3135 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 6007 C3136 (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 6008 C3136 (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 6009 C3138 C3205 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C327 > Page 6010 C3206 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 6021 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 6029 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 6030 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 6031 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 6032 Relay Box: Locations Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6033 Relay Box: Diagrams C270A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6034 C270B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6035 C270C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6036 C270D Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6037 C270E Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6038 C270F C270G Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6039 C270H Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6040 C270J Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6041 C270K Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6042 C270M Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6043 C270N C270P Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 6046 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 6047 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 6048 Relay Box: Application and ID Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 6049 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 6054 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 6055 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 6056 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 6057 Relay Box: Locations Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6058 Relay Box: Diagrams C270A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6059 C270B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6060 C270C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6061 C270D Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6062 C270E Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6063 C270F C270G Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6064 C270H Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6065 C270J Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6066 C270K Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6067 C270M Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6068 C270N C270P Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F1 - F21 Fuse F22 - F42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 6071 Fuse F101 - F401 Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) Fuse F01 - F17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 6072 Fuse F18 - F32 Fuse F33 - F115 Fuse F116 - R305 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 6073 Relay Box: Application and ID Auxiliary Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Power Distribution Box / Central Junction Box (CJB) > Page 6074 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications Alignment: Specifications Alignment Specifications Alignment Specifications Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 6080 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 6081 Alignment: Specifications General Specifications General Specifications Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 6082 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 6083 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 6084 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 6085 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 6086 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 6087 Alignment: Specifications Torque Specifications Torque Specifications Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6088 Alignment: Description and Operation Wheel Alignment Angles Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications in this section will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Toe Positive Toe (Toe In) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6089 Negative Toe (Toe Out) The vehicle toe setting affects tire wear and directional stability. Incorrect Thrust Angle (Dogtracking) Incorrect thrust angle (dogtracking) is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Wander Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down a level road. Shimmy Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6090 Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph) and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface. Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and observed by the driver as small rotational oscillations of the steering wheel. For wheel and tire diagnosis, refer to Section 204-04. Poor Returnability/Sticky Steering Poor returnability and sticky steering is used to described the poor return of the steering wheel to center after a turn or the steering correction is completed. Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (for example: wind, road crown). Poor Groove Feel Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20 degrees of steering wheel turn). Efforts may be said to be "flat on center." ^ Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. ^ In the diagnosis of a roadability problem, it is important to understand the difference between wander and poor groove feel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Alignment: Service and Repair Camber and Caster Adjustment Camber and Caster Adjustment 1. Using alignment equipment and the manufacturer's instruction, measure the caster and camber. 2. NOTE: New lower arm-to-frame mounting bolts must be installed with cam bolt kits to allow for adjustment of the arm in the frame slot. NOTE: The rear lower control arm-to-frame bolt must be reversed in order to install the alignment kit to allow access for a torque wrench. Remove the nuts and bolts from the LH and RH lower control arms at the frame attachments. ^ Discard the nuts and bolts. ^ Loosen the LH and RH stabilizer bar-to-frame bracket nuts. Support the stabilizer bar. ^ Install the cam bolt kit(s) and snug the nut(s). 3. To adjust the caster and camber, refer to the chart. ^ Adjustments that require moving the front and the rear of the lower arm should be made equally. 4. While holding the cam bolt, tighten the nut(s). 5. Recheck the caster and camber settings and adjust as necessary. 6. Check and, if necessary, adjust the front toe. 7. Tighten the LH and RH stabilizer bar bracket nuts to 48 Nm (35 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 6093 8. Set the final torque to 300 Nm (222 lb-ft) on the nuts only. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 6094 Alignment: Service and Repair Ride Height Measurement Ride Height Measurement Front Ride Height Measurement NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure. Vehicle should have at least 1/2 tank of fuel. 1. Position a suitable surface gauge (such as Starrett 57D Surface Gauge) on a flat, level surface and adjust the gauge's arm until the scriber point is located in the center of the rearward lower arm bolt. ^ Lock the surface gauge in this position. 2. With the surface gauge positioned on a flat, level surface, record the measurement of the surface gauge position (measurement A). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 6095 3. Position the surface gauge on the same flat, level surface as used in Step 1 and adjust the gauge's arm until the scriber point is located at the lowest point on the wheel knuckle. ^ Lock the surface gauge in this position. 4. With the surface gauge positioned on a flat, level surface, record the measurement of the surface gauge position (measurement B). 5. Subtract measurement B from measurement A to obtain the front ride height. ^ Refer to Specifications. Rear Ride Height Measurement, Rear Wheel Drive (RWD) vehicles Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 6096 NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure. Vehicle should have at lease 1/2 tank of fuel. 1. Measure the distance between the rear axle jounce stop (Item 2) and the top of the rear axle tube (Item 3) to obtain the rear ride height (Item 1). Rear Ride Height Measurement, Four Wheel Drive (4WD) vehicles NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure. Vehicle should have at lease 1/2 tank of fuel. 1. Measure the distance between the rear axle jounce stop (Item 2) and the top of the rear spring spacer (Item 3) to obtain the rear ride height (Item 1). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 6097 Alignment: Service and Repair Toe Adjustment - Front Toe Adjustment - Front 1. Using alignment equipment and the manufacturer's instructions, measure the toe. 2. Start the engine and center the steering wheel. 3. Turn the engine OFF, and hold the steering wheel in the straight-ahead position using a suitable holding device. 4. NOTE: Do not allow the steering gear bellows to twist when the front wheel spindle tie rod is rotated. Remove the outer bellows clamps. 5. Loosen the tie-rod jam nuts. 6. Rotate the inner tie rods. 7. CAUTION: Make sure to hold the tie-rod end stationary with a wrench while tightening the nut or damage to the boot can occur. NOTE: Make sure that the toe settings are not disturbed while tightening the jam nuts. Tighten the tie-rod jam nuts to 70 Nm (52 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 6098 8. Install the clamps. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Locations Tire Pressure Module: Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Locations > Page 6104 View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Locations > Page 6105 Tire Pressure Module: Diagrams C3008A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Locations > Page 6106 C3008B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 6112 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 6113 C1311 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 6114 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example, during parking maneuvers. Power Steering Pressure (PSP) Switch Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the vehicle security module (VSM). Refer to Tire Pressure Monitoring System (TPMS) Sensor Activation. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Programming and Relearning NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with tire pressure monitor system (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the activation tool, attempt to activate the same sensor with the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least 1/4 of a turn and attempt to activate the same sensor again. NOTE: The VSM has a 2 minute time limit between sensor responses. If the VSM does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the tire pressure must be adjusted and the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressures for front and rear tires, tire rotation will not affect the system. 1. NOTE: Click here to view an animated version of this procedure. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. ^ The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the activation tool must remain in place 180 degrees from the valve stem. Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the special tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the VSM. Click here to view an animated version of this procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 6120 7. Within 2 minutes of the horn sounding, place the activation tool on the RF tire sidewall opposite (180°) from the valve stem to train the RF tire pressure sensor. 8. NOTE: Do not wait more than 2 minutes between training each sensor or the VSM will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor IDs trained to the VSM and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the VSM to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed VSM. If the sensors are being trained due to the installation of a new VSM, clear any DTCs and perform the VSM on-demand self test. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 6121 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool against the LF tire sidewall 180 degrees from the tire valve stem. 3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the activation tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. 1. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. Click here to view an animated version of this procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6124 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. Click here to view an animated version of this procedure. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor may occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6125 3. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6126 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6127 Part 1 Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter, but all strap kits share the same base part number. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. Remove a factory installed strap in the following sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item on both sides of the buckle approximately 25 mm (0.98 in) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. 3. To remove a dealer-installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 4. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Click here to view an animated version of this procedure. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers may damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6128 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180 degrees from the valve stem. Click here to view a video version of this procedure. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. Click here to view an animated version of this procedure. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 in) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6129 6. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Wheel Knuckle Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to make sure correct retention of these parts. CAUTION: Do not strike the ball studs to separate them from the wheel knuckle or damage to the ball studs can occur. Lightly tap the wheel spindle to loosen the ball studs. NOTE: Use the holding feature to prevent the stud (outer tie-rod end, lower ball joint and upper ball joint) from turning while removing or installing the nuts. NOTE: The upper ball joint, the lower ball joint and the outer tie-rod end ball studs do not require special tools to separate from the wheel spindle. 1. Remove the wheel bearing and wheel hub. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 6134 2. If equipped, remove the front wheel speed sensor bolt and position the wheel speed sensor aside. ^ To install, tighten to 9 Nm (80 lb-in). 3. Remove and discard the outer tie-rod end nut and detach the tie-rod end from the wheel spindle. ^ To install, tighten to 150 Nm (111 lb-ft). 4. Remove and discard the upper ball joint nut, then detach the upper ball joint from the wheel spindle and remove the wheel spindle. ^ If necessary, remove the brake shield. ^ To install, tighten to 115 Nm (85 lb-ft). 5. Remove and discard the lower ball joint nut and detach the lower ball joint from the wheel spindle. ^ To install, tighten to 150 Nm (111 lb-ft). 6. To install, reverse the removal procedure. 7. Check and, if necessary, align the front end. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Power Steering System Purging CAUTION: If the air is not purged from the power steering system correctly, premature power steering pump failure may result. The condition may occur on pre-delivery vehicles with evidence of aerated fluid or on vehicles that have had steering component repairs. 1. NOTE: A whine heard from the power steering pump can be caused by air in the system. The power steering purge procedure must be carried out prior to any component repair for which power steering noise complaints are accompanied by evidence of aerated fluid. Remove the power steering pump reservoir cap. Check the fluid. 2. Raise the front wheels off the floor. 3. Tightly insert the stopper of the vacuum pump into the reservoir. 4. Start the engine. 5. Install the vacuum pump, apply vacuum and maintain the maximum vacuum of 68-85 kPa (20-25 in-Hg). 6. If equipped with Hydro-Boost, apply the brake pedal twice. 7. CAUTION: Do not hold the steering wheel against the stops for an extended amount of time. Damage to the power steering pump may occur. Cycle the steering wheel fully from stop-to-stop 10 times. 8. Stop the engine. 9. Release the vacuum and remove the vacuum pump. 10. NOTE: Do not overfill the reservoir. Fill the reservoir. ^ Use approved transmission fluid. 11. Start the engine. 12. Install the vacuum pump. Apply and maintain the maximum vacuum of 68-85 kPa (20-25 in-Hg). 13. CAUTION: Do not hold the steering wheel against the stops for an extended amount of time. Damage to the power steering pump may occur. Cycle the steering wheel fully from stop-to-stop 10 times. 14. Stop the engine, release the vacuum and remove the vacuum pump. 15. NOTE: Do not overfill the reservoir. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 6139 Fill the reservoir as needed and install the reservoir cap. 16. Visually inspect the power steering system for leaks. 17. NOTE: Do not overfill the reservoir. Fill the reservoir as needed and visually inspect the power steering system for leaks. 18. Install the reservoir cap. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications Power Steering Fluid: .......................................................................................................................... ...................................... Motorcraft MERCON ATF Ford Part Number: .............................................. .................................................................................................................................................. XT-5-QM Ford Specifications: ............................................................................................................. .............................................................................. MERCON V Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Page 6143 Power Steering Fluid: Testing and Inspection Power Steering Fluid Leak Test NOTE: This test should only be carried out if a leak in the system has not been detected during a thorough visual inspection. Refer to Inspection and Verification. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Inspection and Verification 1. Check the power steering fluid level. If necessary, add the specified power steering fluid. 2. Remove the power steering pump reservoir cap and tightly install the evacuation cap to the power steering pump reservoir. 3. Install the hose from the fill adapter manifold tee to the evacuation cap on the power steering pump reservoir. 4. Install the vacuum pump to the evacuation cap. 5. Using the vacuum pump, apply 68-85 kPa (20-25 in-Hg) of vacuum to the power steering system. 6. Observe the vacuum gauge for 30 seconds. If the vacuum gauge reading drops more than 3 kPa (0.88 in-Hg) a leak is present. 7. Remove the vacuum pump. 8. CAUTION: Do not hold the steering wheel at the stops for an extended amount of time. Damage to the power steering pump may occur. Start the engine. With the engine at idle, raise the power steering fluid temperature to 74-80°C (165-176°F) by rotating the steering wheel fully to the left and right several times. 9. Visually inspect the system for leaks. If a leak is evident, repair as necessary. If a leak is not evident, add the specified UV fluorescent tracer dye to the power steering fluid. Use 14.78 mL (1/2 oz) of dye solution for every 1.89L (2 qt) of power steering fluid. 10. CAUTION: Do not hold the steering wheel at the stops for an extended amount of time. Damage to the power steering pump may occur. Start the engine. With the engine at idle, raise the power steering fluid temperature to 74-80°C (165-176°F) by rotating the steering wheel fully to the left and right several times. 11. Using the special tool (UV lamp), inspect the system for traces of UV dye. Repair as necessary. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair Power Steering Fluid Cooler: Service and Repair Power Steering Fluid Cooler Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Page 6147 Part 2 Removal and Installation 1. CAUTION: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result. With the vehicle in NEUTRAL, position it on a hoist. 2. Using a suitable suction device, remove the power steering fluid from the fluid reservoir. 3. Release the power steering fluid cooler-to-reservoir hose clamp and disconnect the hose from the power steering fluid reservoir. 4. Remove the steering line clamp plate bolt, rotate the clamp plate and disconnect the power steering fluid cooler from the steering gear. ^ To install, tighten to 23 Nm (17 lb-ft). 5. Remove the 2 power steering fluid cooler bolts and the cooler. ^ To install, tighten to 11 Nm (8 lb-ft). 6. To install, reverse the removal procedure. ^ Fill the power steering system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair Power Steering Fluid Reservoir: Service and Repair Power Steering Fluid Reservoir Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Page 6151 Part 2 Removal and Installation 1. CAUTION: While repairing the power steering system, care should be taken to prevent the entry of foreign materials or failure of the power steering components may result. Using a suitable suction device, remove the power steering fluid from the fluid reservoir. 2. Remove the 3 power steering fluid reservoir bolts. ^ To install, tighten to 11 Nm (8 lb-ft). 3. Release the clamp and disconnect the power steering pump supply hose. 4. Release the clamp and disconnect the return hose. 5. Remove the power steering fluid reservoir. 6. To install, reverse the removal procedure. ^ Fill the power steering system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 07-21-3 > Oct > 07 > Power Steering - Cold Weather High Pressure Line Leakage Power Steering Line/Hose: Customer Interest Power Steering - Cold Weather High Pressure Line Leakage TSB 07-21-3 10/29/07 HIGH PRESSURE POWER STEERING LINE SEEPAGE - COLD CLIMATES ONLY (EXCLUDING HERITAGE F-150) FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT ISSUE Some 2004-2008 F-150 (Excluding Heritage F-150) and 2006-2008 Mark LT vehicles may encounter a concern of a power steering fluid seepage from tears in the high pressure line hose material due to prolonged exposure to -20 °F (-29 °C) and below, specifically climates in areas such as Alaska and Northern Canada. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new service only part has been developed which will resolve this concern on vehicles operating in this environment. Use of the part in warmer climates may result in increased incidents of steering shudder. Remove and replace the power steering line with the service only part listed, following Work Shop Manual, Section 211-02. NOTE USE OF THIS PART IN WARMER CLIMATES COULD RESULT IN LOW SPEED STEERING SHUDDER AND OTHER NVH RELATED COMPLAINTS. NOTE WHILE REPAIRING THE POWER STEERING SYSTEM, CARE SHOULD BE TAKEN TO PREVENT THE ENTRY OF FOREIGN MATERIAL OR FAILURE OF THE POWER STEERING COMPONENTS MAY RESULT. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072103A 2005-2008 F150 4.2L: 0.8 Hr. Replace The Power Steering Pressure Hose (Do Not Use With 3719A) 072103A 2005-2008 F150 4.6L: 1.4 Hrs. Replace The Power Steering Pressure Hose (Do Not Use With 3719A) 072103A 2005-2008 F150 1.1 Hrs. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 07-21-3 > Oct > 07 > Power Steering - Cold Weather High Pressure Line Leakage > Page 6160 2006-2008 Mark LI 5.4L 3V: Replace The Power Steering Pressure Hose (Do Not Use With 3719A) DEALER CODING CONDITION BASIC PART NO. CODE 3A719 D4 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 07-21-3 > Oct > 07 > Power Steering - Cold Weather High Pressure Line Leakage Power Steering Line/Hose: All Technical Service Bulletins Power Steering - Cold Weather High Pressure Line Leakage TSB 07-21-3 10/29/07 HIGH PRESSURE POWER STEERING LINE SEEPAGE - COLD CLIMATES ONLY (EXCLUDING HERITAGE F-150) FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT ISSUE Some 2004-2008 F-150 (Excluding Heritage F-150) and 2006-2008 Mark LT vehicles may encounter a concern of a power steering fluid seepage from tears in the high pressure line hose material due to prolonged exposure to -20 °F (-29 °C) and below, specifically climates in areas such as Alaska and Northern Canada. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new service only part has been developed which will resolve this concern on vehicles operating in this environment. Use of the part in warmer climates may result in increased incidents of steering shudder. Remove and replace the power steering line with the service only part listed, following Work Shop Manual, Section 211-02. NOTE USE OF THIS PART IN WARMER CLIMATES COULD RESULT IN LOW SPEED STEERING SHUDDER AND OTHER NVH RELATED COMPLAINTS. NOTE WHILE REPAIRING THE POWER STEERING SYSTEM, CARE SHOULD BE TAKEN TO PREVENT THE ENTRY OF FOREIGN MATERIAL OR FAILURE OF THE POWER STEERING COMPONENTS MAY RESULT. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072103A 2005-2008 F150 4.2L: 0.8 Hr. Replace The Power Steering Pressure Hose (Do Not Use With 3719A) 072103A 2005-2008 F150 4.6L: 1.4 Hrs. Replace The Power Steering Pressure Hose (Do Not Use With 3719A) 072103A 2005-2008 F150 1.1 Hrs. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 07-21-3 > Oct > 07 > Power Steering - Cold Weather High Pressure Line Leakage > Page 6166 2006-2008 Mark LI 5.4L 3V: Replace The Power Steering Pressure Hose (Do Not Use With 3719A) DEALER CODING CONDITION BASIC PART NO. CODE 3A719 D4 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose Power Steering Line/Hose: Service and Repair Steering Gear to Fluid Cooler Return Hose Steering Gear to Fluid Cooler Return Hose Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 6169 Part 2 Removal and Installation 1. CAUTION: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result. With the vehicle in NEUTRAL, position it on a hoist. 2. Using a suitable suction device, remove the power steering fluid from the fluid reservoir. 3. Remove the steering line clamp plate bolt, rotate the clamp plate and disconnect the return line. ^ To install, tighten to 23 Nm (17 lb-ft). 4. Release the clamp, disconnect the return hose from the power steering fluid cooler and remove the return line. 5. To install, reverse the removal procedure. ^ Fill the power steering system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 6170 Power Steering Line/Hose: Service and Repair Power Steering Pump to Steering Gear Pressure Line Power Steering Pump to Steering Gear Pressure Line Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Steering Gear to Fluid Cooler Return Hose > Page 6171 Part 2 Removal 1. CAUTION: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the power steering pump pulley. 3. Remove the steering line clamp plate bolt and rotate the plate. 4. Disconnect the pressure line from the steering gear. 5. Remove the pressure line bracket-to-crossmember bolt. 6. Remove the pressure line bracket-to-engine nut. 7. Disconnect the pressure line-to-pump fitting and remove the pressure line. Installation 1. Position the pressure line and connect the pressure line-to-pump fitting. ^ If equipped with 4.6L or 5.4L engine, tighten to 65 Nm (48 lb-ft). ^ If equipped with 4.2L engine, tighten to 20 Nm (15 lb-ft). 2. Install the pressure line bracket-to-engine nut. ^ If equipped with a 4.2L or 4.6L engine, tighten the nut to 12 Nm (9 lb-ft). ^ If equipped with a 5.4L engine, tighten the nut to 40 Nm (30 lb-ft). 3. Install the pressure line bracket-to-crossmember bolt. ^ Tighten to 11 Nm (8 lb-ft). 4. Position the pressure line on the steering gear. 5. Rotate the steering line clamp plate and install the bolt. ^ Tighten to 23 Nm (17 lb-ft). 6. Install the power steering pump pulley. 7. Fill the power steering system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Power Steering Pump: Service and Repair Power Steering Pump Power Steering Pump Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6176 Removal All vehicles 1. CAUTION: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result. Using a suitable suction device, remove the power steering fluid from the fluid reservoir. 2. With the vehicle in NEUTRAL, position it on a hoist. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6177 3. Release the clamp and disconnect the power steering pump supply hose. 4. Remove the power steering pump pulley. 5. Disconnect the pressure line-to-pump fitting and position the pressure line aside. ^ Discard the Teflon seal. 6. Remove the power steering pump. 4.6L, 5.4L engines 7. Remove the 3 power steering pump bolts. 4.2L engine 8. Remove the 4 power steering pump bolts. Installation All vehicles 1. Using the special tool, install a new Teflon seal on the pressure line-to-pump fitting. 4.6L, 5.4L engines 2. Position the power steering pump and install the 3 bolts. ^ Tighten to 25 Nm (18 lb-ft). 4.2L engine 3. Position the power steering pump and install the 4 bolts. ^ Tighten to 25 Nm (18 lb-ft). All vehicles 4. Position the pressure line and connect the pressure line-to-pump fitting. ^ If equipped with a 4.6L or 5.4L engine, tighten to 65 Nm (48 lb-ft). ^ If equipped with a 4.2L engine, tighten to 20 Nm (15 lb-ft). 5. Connect the power steering pump supply hose and install the clamp. 6. Install the power steering pump pulley. ^ Fill the power steering system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6178 Power Steering Pump: Service and Repair Power Steering Pump Pulley Power Steering Pump Pulley Special Tool(s) Removal Exploded View (Part 1) Exploded View (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 6179 Vehicles with 5.4L engine 1. Remove the air cleaner intake pipe. Vehicles with 4.6L engine 2. Remove the cooling fan and shroud. Vehicles with 4.2L engine 3. Remove the air cleaner outlet pipe. All vehicles 4. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the power steering pump pulley. 5. Using the special tool, remove the power steering pump pulley. Installation All vehicles 1. NOTE: Make sure the pulley is flush with the end of the power steering pump shaft. Using the special tool, install the power steering pump pulley. 2. Rotate the accessory drive belt tensioner and install the accessory drive belt on the power steering pump pulley. Vehicles with 4.2L engine 3. Install the air cleaner outlet pipe. Vehicles with 4.6L engine 4. Install the cooling fan and shroud. Vehicles with 5.4L engine 5. Install the air cleaner intake pipe. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 6184 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 6185 C1311 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 6186 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example, during parking maneuvers. Power Steering Pressure (PSP) Switch Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) Depowering Procedure WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, remove the trim panel, the cover and the RCM fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install the RCM fuse 19 (10A) to the CJB and install the cover and trim panel. 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6192 4. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6193 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, remove the trim panel, the cover, and the RCM fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Remove the driver air bag module. 8. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6194 9. While pushing in on the 2 glove compartment door tabs, position the glove compartment downward. 10. Through the glove compartment opening, release the tabs and disconnect the LH passenger air bag module electrical connector. 11. Attach the restraint system diagnostic tool to the vehicle harness side of the LH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6195 12. Through the glove compartment opening, release the tabs and disconnect the RH passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the RH passenger air bag module electrical connector. 14. Install the RCM fuse 19 (10A) to the CJB. 15. Connect the battery ground cable. Reactivation 1. Remove the RCM fuse 19 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the RH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6196 4. Through the glove compartment opening, connect the RH passenger air bag module electrical connector. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the LH passenger air bag module electrical connector. 6. Through the glove compartment opening, connect the LH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6197 7. Close the glove compartment. 8. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 9. Turn the ignition switch from OFF to ON. 10. Install the RCM fuse 19 (10A) to the CJB and install the cover and trim panel. 11. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 12. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Adaptive Collapsible Steering Column > Component Information > Service and Repair Adaptive Collapsible Steering Column: Service and Repair DEPLOYABLE STEERING COLUMN - IN-VEHICLE DEPLOYMENT WARNING: Deploy all supplemental restraint system (SRS) devices (air bags, pretensioners, load limiters, etc.) outdoors with all personnel at least 9.14 meters (30 feet) away to make sure of personal safety. Due to the loud report which occurs when an SRS device is deployed, hearing protection is required. Failure to follow these instructions may result in serious personal injury. 1. Depower the SRS. 2. NOTE: It may be necessary to lower or remove the deployable steering column from the instrument panel to access the deployable steering column electrical connector. Access the deployable steering column electrical connector. 3. NOTE: If the deployable steering column does not have a hard-wired pigtail, it will be necessary to cut the wires and connector(s) from the vehicle wire harness and reconnect to the deployable steering column. Cut each of the deployable steering column wires, leaving at least 4 inches to work with. 4. Remove any sheathing (if present) and strip the insulation from the ends of the cut wires. 5. Make a jumper harness to deploy the deployable steering column. - Obtain 2 wires (20 gauge minimum) at least 9.14 m (30 ft) long and strip both ends of each wire. - At one end of the jumper harness, connect the wires together. 6. Using the end of the jumper harness that the wires are not connected together, attach each wire of the jumper harness to each wire of the deployable steering column. Use tape or other insulating material to make sure that the leads do not make contact with each other. 7. Remain at least 9.14 m (30 ft) away from the deployable steering column. 8. From the end of the jumper harness that is not connected to the deployable steering column, disconnect the 2 wires of the jumper harness from each other. 9. Deploy the deployable steering column by touching the ends of the 2 wires of the jumper harness to the terminals of a 12-volt battery. 10. To allow for cooling, wait at least 10 minutes before approaching the deployed steering column. 11. Dispose of the deployed steering column in the same manner as any other part to be scrapped. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair Steering Column Cover: Service and Repair STEERING COLUMN COVER Exploded View Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Page 6204 Part 2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Page 6205 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Page 6206 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Page 6207 Removal and Installation 1. Remove the steering wheel. 2. Remove the lower steering column cover screw. 3. Remove the lower steering column cover. 4. Remove the 2 upper steering column cover screws. 5. Remove the upper steering column cover. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Steering Gear Valve Test Steering Gear: Testing and Inspection Steering Gear Valve Test Steering Gear Valve Test 1. With the vehicle in motion, place the transmission in NEUTRAL and turn the engine OFF. ^ If the vehicle does not pull with the engine OFF, repair or install a new steering gear. 2. If the vehicle pulls with the engine OFF, switch the right side front wheel to the left side of the vehicle and the left side front wheel to the right side of the vehicle. 3. If the vehicle pulls to the opposite side, switch the front wheels with the rear wheels keeping them on the same side of the vehicle. 4. If the vehicle pull direction does not change, check the front suspension components, wheel alignment and frame alignment. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Steering Gear Valve Test > Page 6212 Steering Gear: Testing and Inspection Steering Gear Grunt/Shudder Test Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1,200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for an extended amount of time. Damage to the power steering pump may occur. Rotate the steering wheel to the RH stop, then turn the steering wheel 90 degrees back from that position. Slowly turn the steering wheel back and forth approximately 1/12 of a full turn. 4. Turn the steering wheel another 90 degrees. Slowly turn the steering wheel back and forth approximately 1/12 of a full turn. 5. Repeat the test with the power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200 Hz) shudder is present, this is a normal steering system condition. 7. If a loud grunt is heard, or a strong shudder is felt, purge the power steering system. If a loud grunt or strong shudder still exists, check the power steering lines/hoses for restrictions or damage and repair as necessary. If the lines/hoses are OK, install a new steering gear. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Page 6213 Steering Gear: Service and Repair Steering Gear Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Page 6214 Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Page 6215 Part 2 Removal CAUTION: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result. NOTE: New O-ring seals must be installed any time the power steering lines are disconnected from the steering gear. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the 4 skid plate bolts and the skid plate. 3. CAUTION: Do not allow the steering column to rotate while the steering column shaft is disconnected or damage to the clockspring may result. If there is evidence that the steering column has rotated, the clockspring must be removed and recentered. Remove the lower steering column shaft-to-steering gear bolt and disconnect the lower steering column shaft. 4. Remove the 2 oil drip shield bolts and the drip shield. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Page 6216 5. NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering gear. Remove the steering line clamp plate bolt and disconnect the pressure line. ^ Discard the O-ring seal. 6. Disconnect the return line. ^ Discard the O-ring seal. 7. Loosen the 2 tie-rod jam nuts. 8. Remove the 2 outer tie-rod end nuts. 9. NOTE: Note the number of times the outer tie-rod ends turn for reference during assembly. Using the special tool, separate the outer tie-rod ends from the wheel knuckles and remove the outer tie-rod ends. 10. Remove the 2 steering gear bracket nuts. 11. Remove the 2 steering gear bracket bolts. 12. Remove the 2 steering gear nuts. 13. Remove the 2 steering gear bolts and the steering gear brackets. 14. Remove the steering gear. ^ Remove the steering gear through the LH wheel opening. Installation 1. Install new O-ring seals on the pressure and return lines. 2. Position the steering gear. ^ Install the steering gear through the LH wheel opening. 3. Install the 2 steering gear brackets and the steering gear bolts and nuts. ^ Tighten to 250 Nm (185 lb-ft). 4. Install the 2 steering gear bracket bolts and nuts. ^ Tighten to 103 Nm (76 lb-ft). 5. Connect the lower steering column shaft to the steering gear and install the lower steering column shaft-to-steering gear bolt. ^ Tighten to 30 Nm (22 lb-ft). 6. Install the 2 outer tie-rod ends on the steering gear. 7. Position the 2 outer tie-rod ends on the wheel knuckles and install the nuts. ^ Tighten to 115 Nm (85 lb-ft). 8. Tighten the 2 tie-rod jam nuts. ^ Tighten to 103 Nm (76 lb-ft). 9. Connect the pressure line and install the steering line clamp plate bolt. ^ Tighten to 23 Nm (17 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Page 6217 10. Position the oil drip shield and install the 2 bolts. ^ Tighten to 10 Nm (89 lb-in). 11. If equipped, install the skid plate and the 4 skid plate bolts. ^ Tighten to 25 Nm (18 lb-ft). 12. Fill the power steering system. ^ Check and, if necessary, adjust the front toe. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair Steering Shaft: Service and Repair Steering Column Shaft Removal and Installation Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Page 6221 Part 2 CAUTION: Do not allow the steering column to rotate while the steering column shaft is disconnected or damage to the clockspring may result. If there is evidence that the steering column has rotated, the clockspring must be removed and recentered. Lower steering column shaft 1. With the vehicle in NEUTRAL, position it on a hoist. Both upper and lower steering column shafts 2. Place the steering wheel in the straight-ahead position and turn the ignition switch to the OFF position. ^ Remove the key. 3. Remove the upper steering column shaft-to-lower steering column shaft bolt and separate the shafts. ^ To install, tighten to 47 Nm (35 lb-ft). Upper steering column shaft 4. Remove the 2 dash seal bolts and the dash seal. ^ To install, tighten to 12 Nm (9 lb-ft). 5. Remove the upper steering column shaft-to-steering column bolt. ^ To install, tighten to 30 Nm (22 lb-ft). 6. Remove the upper steering column shaft. Lower steering column shaft 7. Remove the lower steering column shaft-to-steering gear bolt. ^ To install, tighten to 30 Nm (22 lb-ft). 8. Remove the lower steering column shaft 9. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair Steering Wheel: Service and Repair Steering Wheel Special Tool Removal and Installation CAUTION: Removing the steering wheel without using a puller can damage the column bearings. NOTE: Due to manufacturing differences, the original steering wheel locating splines may not match a replacement steering wheel. If the steering wheel is not centered after a new steering wheel has been installed, a front toe adjustment will be required. 1. Place the steering wheel in the straight-ahead position and turn the ignition switch to the OFF position. 2. Remove the driver air bag module. 3. Disconnect the steering wheel switches electrical connector. 4. NOTE: Do not remove the bolt until the steering wheel has been separated from the column. Loosen the steering wheel bolt. 5. Using the special tool, separate the steering wheel from the steering column assembly. 6. Remove the steering wheel bolt and the steering wheel. ^ To install, tighten to 40 Nm (30 ft. lbs.). 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair Tie Rod: Service and Repair Inner Tie Rod Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Page 6228 Part 2 Removal CAUTION: The steering gear boots and clamps are designed to produce an airtight seal and protect the internal components of the steering gear. If the seal is not airtight, the vacuum generated during turning will draw water and foreign material into the gear, causing damage. Zip ties do not provide an airtight seal and must not be used CAUTION: The inner tie-rod ball joint grease is not compatible with water. Water trapped in the grease will damage the joint. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Loosen the tie-rod jam nut. 3. Remove the outer tie-rod end nut. 4. Using the special tool, separate the outer tie-rod end from the wheel knuckle. 5. NOTE: Note the number of times the outer tie-rod ends turn for reference during assembly. Remove the outer tie-rod end. 6. Remove the tie-rod jam nut from the inner tie rod. 7. Remove the outer bellows boot clamp. 8. Remove and discard the inner bellows boot clamp. 9. CAUTION: If present, the orientation of the vent tube must be noted so the boots and vent tubes may be installed in the correct location. Incorrect venting may lead to internal component damage. Remove the steering gear bellows boot. 10. If removing the RH inner tie rod, position the LH outer bellows boot clamp from the LH steering gear bellows boot. 11. If removing the RH inner tie rod, remove and discard the LH inner bellows boot clamp and position the LH steering gear bellows boot aside to gain access to the steering gear rack. 12. CAUTION: Place the steering gear at the center position. Use an appropriate-sized wrench on the flat of the rack gear to resist rotation and to prevent damage during the removal of the inner tie rod. NOTE: An assistant may be needed for removal of the RH inner tie rod. Using an appropriate-sized crow's foot wrench, remove the inner tie rod. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Page 6229 Installation 1. CAUTION: Thoroughly remove any abrasive material. This material is extremely harmful to the steering gear. Thoroughly clean and inspect all parts to be reused. Replace any parts as necessary. 2. CAUTION: Place the steering gear at the center position. Use an appropriate-sized wrench on the flat of the rack gear to resist rotation and to prevent damage during the installation of the inner tie rod. NOTE: An assistant may be needed for installation of the RH inner tie rod. Using an appropriate-sized crow's foot wrench, install the inner tie rod. ^ Tighten to 100 Nm (74 lb-ft). 3. NOTE: Lubricate the inner tie-rod groove with steering gear grease where the steering gear bellows boot is clamped. Install the steering gear bellows boot. 4. Using the special tool, install the inner bellows boot clamp. 5. If installing the RH inner tie rod, position the LH steering gear bellows boot onto the steering gear. 6. If installing the RH inner tie rod, use the special tool and install the LH inner bellows boot clamp. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Page 6230 7. NOTE: Make sure the end of the bellows boot is positioned between the groove on the inner tie rod or an internal leak can result. If installing the RH inner tie rod, position the LH outer bellows boot clamp onto the LH steering gear bellows boot. 8. NOTE: Make sure the end of the bellows boot is positioned between the groove on the inner tie rod or an internal leak can result. Install the outer bellows boot clamp. 9. Install the tie-rod jam nut on the inner tie rod. 10. Install the outer tie-rod end and the outer tie-rod end nut. ^ Tighten to 115 Nm (85 lb-ft). 11. Tighten the tie-rod jam nut. ^ Tighten to 103 Nm (76 lb-ft). 12. Check and if necessary, adjust the front toe. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection Ball Joint: Testing and Inspection Ball Joint Inspection 1. Prior to inspecting the ball joints for wear, inspect the wheel bearings. 2. NOTE: In order to obtain accurate measurements, the suspension must be in full rebound with the weight of the vehicle supported by the frame. Raise and support the vehicle by the frame to allow the wheels to hang in the rebound position. 3. Inspect the ball joint and ball joint boot for damage. ^ If the ball joint or ball joint boot is damaged, install a new ball joint as necessary. NOTE: Carry out Steps 4-6 to inspect the lower ball joint. Carry out Steps 7-9 to inspect the upper ball joint. 4. CAUTION: Do not use any tools or equipment to move the wheel and tire assembly or suspension components while checking for relative movement. Suspension damage can occur. The use of tools or equipment will also create relative movement that may not exist when using hand force. Relative movement must be measured using hand force only. NOTE: The weight of the wheel and tire assembly must be overcome to obtain an accurate measurement on the dial indicator. Inspect the ball joint for relative movement by alternately pulling downward and pushing upward on the wheel and tire assembly by hand. Note any relative vertical movement between the wheel knuckle and lower arm at the lower ball joint. ^ If relative movement is not felt or seen, the ball joint is OK. Do not install a new ball joint. ^ If relative movement is found, continue with Step 5. 5. NOTE: In order to obtain an accurate measurement, the dial indicator should be aligned as close as possible with the vertical axis (center line) of the ball joint. To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the lower control arm and the wheel knuckle or ball joint stud. 6. Measure the ball joint deflection while an assistant pushes up and pulls down on the wheel and tire assembly, by hand. ^ If the deflection exceeds the specification, a new ball joint must be installed. ^ If the deflection meets or is below the specification, continue with the procedure. 7. CAUTION: Do not use any tools or equipment to move the wheel and tire assembly or suspension components while checking for relative movement. Suspension damage can occur. The use of tools or equipment will also create relative movement that may not exist when using hand force. Relative movement must be measured using hand force only. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 6235 Inspect the ball joint for relative movement by alternately pulling downward and pushing upward on the upper control arm by hand. Note any relative vertical movement between the wheel knuckle and upper arm at the upper ball joint. ^ If relative movement is not felt or seen, the ball joint is OK. Do not install a new ball joint. ^ If relative movement is found, continue with Step 8. 8. NOTE: In order to obtain an accurate measurement, the dial indicator should be aligned as close as possible with the vertical axis of the ball joint. To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the upper control arm and the wheel knuckle or ball joint stud. 9. Measure the ball joint deflection while an assistant pushes up and then pulls down on the upper control arm, by hand. ^ If the deflection exceeds the specification, a new ball joint must be installed. ^ If the deflection meets or is below the specification, no further action is required. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower Arm Control Arm: Service and Repair Lower Arm Lower Arm Lower Arm Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to make sure correct retention of these parts. NOTE: Use the holding feature to prevent the ball studs (lower ball joint and stabilizer bar link) from turning while removing the nuts. 1. Remove the wheel and tire. 2. CAUTION: Do not strike the ball joint stud to separate it from the wheel spindle or damage to the ball stud can occur. Lightly tap the wheel spindle to loosen the ball stud. NOTE: The lower ball joint does not require special tools to separate from the wheel spindle. Remove and discard the lower ball joint nut and separate the ball joint from the wheel spindle. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower Arm > Page 6240 3. Remove and discard the stabilizer bar link lower nut. 4. Remove and discard the shock absorber lower nut and bolt. 5. Remove the lower arm nuts, bolts and the lower arm. ^ Discard the nuts and bolts. Installation NOTE: Use the holding feature to prevent the ball studs (lower ball joint and stabilizer bar link) from turning while installing the nuts. 1. NOTE: Do not tighten the lower arm nuts at this time. Install the lower arm and loosely install the lower arm bolts and nuts. 2. Position the lower ball joint into the wheel spindle and install the nut. ^ Tighten to 150 Nm (111 lb-ft). 3. Install the shock absorber lower nut and bolt. ^ Tighten the nut to 475 Nm (351 lb-ft). 4. Install the stabilizer bar link lower nut. ^ Tighten to 90 Nm (66 lb-ft). 5. Install the wheel and tire. 6. With the weight of the vehicle resting on the wheels and tires, tighten the lower arm nuts to 350 Nm (258 lb-ft). 7. Check and, if necessary, align the front end. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower Arm > Page 6241 Control Arm: Service and Repair Upper Arm Upper Arm Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to make sure correct retention of these parts. 1. Remove the shock absorber and spring assembly. 2. CAUTION: Do not strike the ball joint stud to separate it from the wheel spindle or damage to the ball stud can occur. Lightly tap the wheel spindle to loosen the ball stud. NOTE: Use the holding feature to prevent the upper arm ball joint stud from turning while removing the nut. NOTE: The upper ball joint does not require special tools to separate from the wheel spindle. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower Arm > Page 6242 Remove and discard the upper ball joint nut and separate the ball joint from the wheel spindle. Installation 1. NOTE: Do not tighten the nuts at this time. Position the upper arm and loosely install the upper arm bolts and nuts. 2. CAUTION: Use the holding feature to prevent the upper arm ball joint stud from turning while installing the nut. Connect the ball joint to the wheel spindle and install the upper ball joint nut. ^ Tighten to 115 Nm (85 lb-ft). 3. Install the shock absorber and spring assembly. 4. With the weight of the vehicle resting on the wheels and tires, tighten the upper arm nuts to 150 Nm (111 lb-ft). 5. Check and, if necessary, align the front end. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair Cross-Member: Service and Repair TRANSMISSION SUPPORT CROSSMEMBER Transmission Support Crossmember Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 2 exhaust hanger bolts. - To install, tighten to 40 Nm (30 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Page 6246 3. Remove the 2 heat shield screws. - To install, tighten to 20 Nm (15 lb-ft). 4. Support the transmission with a suitable jack. 5. Remove the 2 transmission support nuts. - To install, tighten to 103 Nm (76 lb-ft). 6. Remove the 4 transmission support crossmember bolts. - To install, tighten to 115 Nm (85 lb-ft). 7. Remove the transmission support crossmember. 8. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Wheel Knuckle Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to make sure correct retention of these parts. CAUTION: Do not strike the ball studs to separate them from the wheel knuckle or damage to the ball studs can occur. Lightly tap the wheel spindle to loosen the ball studs. NOTE: Use the holding feature to prevent the stud (outer tie-rod end, lower ball joint and upper ball joint) from turning while removing or installing the nuts. NOTE: The upper ball joint, the lower ball joint and the outer tie-rod end ball studs do not require special tools to separate from the wheel spindle. 1. Remove the wheel bearing and wheel hub. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 6250 2. If equipped, remove the front wheel speed sensor bolt and position the wheel speed sensor aside. ^ To install, tighten to 9 Nm (80 lb-in). 3. Remove and discard the outer tie-rod end nut and detach the tie-rod end from the wheel spindle. ^ To install, tighten to 150 Nm (111 lb-ft). 4. Remove and discard the upper ball joint nut, then detach the upper ball joint from the wheel spindle and remove the wheel spindle. ^ If necessary, remove the brake shield. ^ To install, tighten to 115 Nm (85 lb-ft). 5. Remove and discard the lower ball joint nut and detach the lower ball joint from the wheel spindle. ^ To install, tighten to 150 Nm (111 lb-ft). 6. To install, reverse the removal procedure. 7. Check and, if necessary, align the front end. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair Stabilizer Link: Service and Repair Stabilizer Bar and Link Stabilizer Bar And Link Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to make sure correct retention of these parts. NOTE: Use the holding feature to prevent the studs from turning while removing or installing the stabilizer bar link nuts. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the stabilizer bar link upper nuts. 3. Remove and discard the stabilizer bar link lower nuts and the stabilizer bar links. 4. Remove and discard the stabilizer bar bracket nuts, brackets and the stabilizer bar. Installation Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Page 6255 NOTE: When installing the stabilizer bar, make sure that the bar is centered symmetrically between the 2 stabilizer bar brackets. The distance between the stabilizer bar bracket and link, should be the same on both sides. NOTE: When installing the stabilizer bar, make sure that the paint dot is on the LH side of the vehicle. 1. Install the stabilizer bar and brackets and loosely install the bracket nuts. 2. Install the stabilizer bar link and lower nuts. ^ Tighten to 90 Nm (66 lb-ft). NOTE: When installing the stabilizer bar onto the link assembly, make sure the bar is perpendicular to the stabilizer link when tightening the nut or the stabilizer link nut may not correctly seat. 3. Install the stabilizer bar onto the stabilizer link assembly with the bar positioned perpendicular to the link assembly. 4. Install the stabilizer bar link upper nuts. ^ Tighten to 25 Nm (18 lb-ft). 5. Center the stabilizer bar and tighten the stabilizer bar bracket nuts to 55 Nm (41 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement Suspension Spring ( Coil / Leaf ): Removal and Replacement Front Shock Absorber and Spring Assembly Shock Absorber and Spring Assembly Removal WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may result in serious personal injury. WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts can extend unassisted. Failure to follow this instruction may result in serious personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to make sure correct retention of these parts. 1. Remove the wheel and tire. 2. Remove and discard the 3 shock absorber upper mount nuts. 3. CAUTION: Do not hammer the outer tie-rod end ball stud to separate the outer tie-rod end from the wheel spindle or damage to the ball stud can occur. Lightly tap the wheel spindle to loosen the ball stud. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 6260 NOTE: Use the holding feature to prevent the outer tie-rod end ball stud from turning while removing the nut. Remove and discard the outer tie-rod end nut and separate the tie-rod end from the wheel spindle. 4. NOTE: Position the outer tie rod end as necessary to remove the shock absorber and spring assembly. Remove the shock absorber lower nut, bolt and the shock absorber and spring assembly. ^ Discard the nut and bolt. 5. For additional information regarding disassembly and assembly of the shock absorber and spring assembly, refer to Shock Absorber and Spring Assembly. Installation 1. NOTE: Do not tighten the lower shock nut at this time. Install the shock absorber and spring assembly and loosely install the shock absorber lower bolt and nut. 2. NOTE: Use the holding feature to prevent the outer tie-rod end ball stud from turning while installing the nut. Position the outer tie-rod end and install the nut. ^ Tighten to 150 Nm (111 lb-ft). 3. Install the 3 shock absorber upper mount nuts. ^ Tighten to 48 Nm (35 lb-ft). 4. Install the wheel and tire. 5. With the weight of the vehicle resting on the wheels and tires, tighten the shock absorber lower nut to 475 Nm (351 lb-ft). Rear Spring Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 6261 Spring Removal WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may result in serious personal injury. WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts can extend unassisted. Failure to follow this instruction may result in serious personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 6262 result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to make sure correct retention of these parts. 1. Remove the wheel and tire. 2. Using a suitable jack, support the axle. 3. Remove and discard the shock absorber lower nut and bolt. 4. Remove the 4 U-bolt nuts, the U-bolt plate and the 2 U-bolts. ^ Discard the nuts and the U-bolts. 5. NOTE: If removing the left rear spring, lower the fuel tank to gain access to the spring shackle-to-frame bolt. NOTE: If removing the right rear spring, remove the muffler to gain access to the spring-to-frame bolt. Remove and discard the spring-to-frame nut and bolt. 6. Remove and discard the spring shackle-to-frame nut and bolt. 7. NOTE: Only lower the axle enough to gain access to remove the spring. Lower the jack and remove the spring and shackle. 8. If necessary, remove the spring-to-shackle nut, bolt and spring shackle. ^ Discard the nut and bolt. Installation All vehicles 1. If necessary, position the spring and install the shackle-to-spring bolt and nut. ^ Tighten until snug. 2. Install the spring shackle-to-frame bolt and nut. ^ Tighten until snug. 3. Position the U-bolt plate and install the U-bolts and nuts. ^ Tighten until snug. 4. NOTE: On four wheel drive (4WD) vehicles, make sure the spacer is correctly seated between the axle and spring, with the nose pointed inward. Install the spring-to-frame bolt and nut. ^ Tighten until snug. 5. Install the shock absorber bolt and nut. ^ Tighten until snug. 6. Install the wheel and tire. 7. Lower the vehicle until the weight of the vehicle is resting on the wheels and tires (curb height). 8. Tighten the spring shackle-to-frame nut to 133 Nm (98 lb-ft). 9. Tighten the spring-to-shackle nut to 133 Nm (98 lb-ft). 10. NOTE: If installing the left rear spring, raise the fuel tank. NOTE: If installing the right rear spring, install the muffler. Tighten the spring-to-frame nut and bolt to 350 Nm (258 lb-ft). Light duty vehicles 11. Tighten the U-bolt nuts in 4 stages. ^ Stage 1: Tighten in a cross pattern to 35 Nm (26 lb-ft). ^ Stage 2: Tighten in a cross pattern to 70 Nm (52 lb-ft). ^ Stage 3: Tighten in a cross pattern to 100 Nm (74 lb-ft). ^ Stage 4: Tighten in a cross pattern to 133 Nm (98 lb-ft). Heavy duty vehicles 12. Tighten the U-bolt nuts in 4 stages. ^ Stage 1: Tighten in a cross pattern to 63 Nm (46 lb-ft). ^ Stage 2: Tighten in a cross pattern to 125 Nm (92 lb-ft). ^ Stage 3: Tighten in a cross pattern to 188 Nm (139 lb-ft). ^ Stage 4: Tighten in a cross pattern to 250 Nm (184 lb-ft). All vehicles 13. Tighten the shock absorber lower nut to 90 Nm (66 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 6263 Suspension Spring ( Coil / Leaf ): Overhaul Shock Absorber and Spring Assembly Shock Absorber And Spring Assembly Disassembly and Assembly WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may result in serious personal injury. WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts can extend unassisted. Failure to follow this instruction may result in serious personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to make sure correct retention of these parts. 1. Remove the shock absorber and spring assembly. 2. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 6264 3. Index-mark the shock absorber upper mount and isolator. 4. NOTE: Use the holding feature to prevent the rod from turning while removing or installing the nut. While holding the shock absorber rod, remove the nut and the shock absorber. ^ Discard the nut. ^ To install, tighten to 30 Nm (22 lb-ft). 5. Remove the shock absorber upper mount. 6. Remove the insulator. 7. Remove the dust tube. 8. Carefully release the spring compressor and remove the coil spring. 9. NOTE: When installing the spring onto the shock absorber, make sure the lower seat and spring are aligned with the lower shock bolt hole. NOTE: When installing the upper mount onto the spring isolator, make sure to align the index marks made during disassembly. To assemble, reverse the disassembly procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement Suspension Strut / Shock Absorber: Removal and Replacement Front Suspension Shock Absorber and Spring Assembly Shock Absorber and Spring Assembly Removal WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may result in serious personal injury. WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts can extend unassisted. Failure to follow this instruction may result in serious personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to make sure correct retention of these parts. 1. Remove the wheel and tire. 2. Remove and discard the 3 shock absorber upper mount nuts. 3. CAUTION: Do not hammer the outer tie-rod end ball stud to separate the outer tie-rod end from the wheel spindle or damage to the ball stud can occur. Lightly tap the wheel spindle to loosen the ball stud. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6269 NOTE: Use the holding feature to prevent the outer tie-rod end ball stud from turning while removing the nut. Remove and discard the outer tie-rod end nut and separate the tie-rod end from the wheel spindle. 4. NOTE: Position the outer tie rod end as necessary to remove the shock absorber and spring assembly. Remove the shock absorber lower nut, bolt and the shock absorber and spring assembly. ^ Discard the nut and bolt. 5. For additional information regarding disassembly and assembly of the shock absorber and spring assembly, refer to Shock Absorber and Spring Assembly. Installation 1. NOTE: Do not tighten the lower shock nut at this time. Install the shock absorber and spring assembly and loosely install the shock absorber lower bolt and nut. 2. NOTE: Use the holding feature to prevent the outer tie-rod end ball stud from turning while installing the nut. Position the outer tie-rod end and install the nut. ^ Tighten to 150 Nm (111 lb-ft). 3. Install the 3 shock absorber upper mount nuts. ^ Tighten to 48 Nm (35 lb-ft). 4. Install the wheel and tire. 5. With the weight of the vehicle resting on the wheels and tires, tighten the shock absorber lower nut to 475 Nm (351 lb-ft). Rear Suspension Shock Absorber Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6270 Shock Absorber WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may result in serious personal injury. WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts can extend unassisted. Failure to follow this instruction may result in serious personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to make sure correct retention of these parts. 1. Remove the wheel and tire. 2. Using a suitable jack, support the axle. 3. Remove and discard the shock absorber upper nut and bolt. ^ To install, tighten to 90 Nm (66 lb-ft). 4. Remove the shock absorber lower nut, lower bolt and the shock absorber. ^ Discard the nut and bolt. ^ To install, tighten to 90 Nm (66 lb-ft). 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6271 Suspension Strut / Shock Absorber: Overhaul Shock Absorber and Spring Assembly Shock Absorber And Spring Assembly Disassembly and Assembly WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may result in serious personal injury. WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts can extend unassisted. Failure to follow this instruction may result in serious personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to make sure correct retention of these parts. 1. Remove the shock absorber and spring assembly. 2. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 6272 3. Index-mark the shock absorber upper mount and isolator. 4. NOTE: Use the holding feature to prevent the rod from turning while removing or installing the nut. While holding the shock absorber rod, remove the nut and the shock absorber. ^ Discard the nut. ^ To install, tighten to 30 Nm (22 lb-ft). 5. Remove the shock absorber upper mount. 6. Remove the insulator. 7. Remove the dust tube. 8. Carefully release the spring compressor and remove the coil spring. 9. NOTE: When installing the spring onto the shock absorber, make sure the lower seat and spring are aligned with the lower shock bolt hole. NOTE: When installing the upper mount onto the spring isolator, make sure to align the index marks made during disassembly. To assemble, reverse the disassembly procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications SPINDLE BEARING LUBRICANT Premium Long-Life Grease Ford Part Number ..................................................................................................................................... XG-1-C or XG-1-K (US); CXG-1-C (Canada) Ford Specification .......................................................................... ............................................................................................................ ESA-M1C75-B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Wheel Bearing and Wheel Hub Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to make sure correct retention of these parts. 1. Remove the wheel and tire. 2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the 2 bolts and position the caliper and anchor plate assembly aside. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 200 Nm (148 lb-ft). 3. Remove the cotter pin and wheel hub nut retainer. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6278 ^ Discard the cotter pin. 4. Remove and discard the wheel hub nut. ^ To install, tighten to 400 Nm (296 lb-ft). 5. Remove the brake disc/wheel bearing and wheel hub assembly. 6. CAUTION: Do not apply lubricant to the threaded end of the wheel spindle or incorrect clamp load may occur. NOTE: Clean the wheel spindle (including the threaded end) of any dirt or grease using the specified solvent before installing the brake disc. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6279 Wheel Bearing: Service and Repair Rear Ford 8.8-Inch Ring Gear Rear Wheel Bearing and Axle Shaft Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6280 Removal 1. Remove the axle shaft. 2. NOTE: If the axle shaft oil seal is leaking, the axle housing vent may be plugged with foreign material. NOTE: Use care to avoid damaging the axle shaft oil seal bore. Using a suitable seal remover, remove and discard the axle shaft oil seal. 3. Inspect the rear wheel bearing and axle shaft for wear or damage. 4. If necessary, using the special tools, remove the rear wheel bearing. Installation 1. If removed, lubricate the new rear wheel bearing with axle lubricant. 2. If removed, use the special tools to install the rear wheel bearing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6281 3. Lubricate the lip of the new axle shaft oil seal with grease. 4. Using the special tools, install the new axle shaft oil seal. 5. Install the axle shaft. Ford 9.75-Inch Ring Gear Rear Wheel Bearing and Axle Shaft Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6282 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6283 Removal 1. Remove the axle shaft. 2. NOTE: If only a new axle shaft oil seal needs to be installed, use care to avoid damaging the axle shaft oil seal bore. Using a suitable seal remover, remove and discard the axle shaft oil seal. 3. Inspect the rear wheel bearing and axle shaft for wear or damage. 4. Using the special tools, remove the rear wheel bearing. Installation 1. Lubricate the new rear wheel bearing with axle lubricant. 2. Using the special tools, install the rear wheel bearing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6284 3. Lubricate the lip of the new axle shaft oil seal with grease. 4. Using the special tools, install the new axle shaft oil seal. 5. Install the axle shaft. Ford 10.25-Inch Ring Gear Rear Wheel Bearing and Axle Shaft Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6285 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6286 Removal 1. Remove the axle shaft. 2. NOTE: If only a new axle shaft oil seal needs to be installed, use care to avoid damaging the axle shaft oil seal bore. Using a suitable seal remover, remove and discard the axle shaft oil seal. 3. Inspect the rear wheel bearing and axle shaft for wear or damage. 4. Using the special tools, remove the rear wheel bearing. Installation 1. Lubricate the new rear wheel bearing with axle lubricant. 2. Using the special tools, install the rear wheel bearing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6287 3. Lubricate the lip of the new axle shaft oil seal with grease. 4. Using the special tools, install the new axle shaft oil seal. 5. Install the axle shaft. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations View 151-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 6292 C1291 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING AND LIFTING WARNING: - Never get underneath a vehicle that is supported only by a jack. The jack could unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions may result in serious personal injury. - Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand. Failure to follow this instruction may result in serious personal injury. - When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the parking brake if the rear wheels will remain on the ground. These actions help prevent unintended vehicle movement. Failure to follow these instructions may result in serious personal injury. - Position the hoist lift arms as shown in the illustration. Incorrect positioning could result in vehicle slipping or falling from the hoist. Failure to follow this instruction may result in serious personal injury. CAUTION: - Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack. - Position the jack to avoid contact with the fuel tank. Jacking Points - Front CAUTION: Do not use the control arm as a jacking point. Damage to the vehicle may occur. The jacking point is a flat portion on the frame, located behind the front tire and wheel assembly. Jacking Points - Rear CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 6297 The rear jacking points are located on the rear axle. Frame Lifting Points Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Locations Tire Pressure Module: Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Locations > Page 6302 View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Locations > Page 6303 Tire Pressure Module: Diagrams C3008A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Locations > Page 6304 C3008B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the vehicle security module (VSM). Refer to Tire Pressure Monitoring System (TPMS) Sensor Activation. See: Tire Monitoring System/Testing and Inspection/Programming and Relearning NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with tire pressure monitor system (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the activation tool, attempt to activate the same sensor with the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least 1/4 of a turn and attempt to activate the same sensor again. NOTE: The VSM has a 2 minute time limit between sensor responses. If the VSM does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the tire pressure must be adjusted and the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressures for front and rear tires, tire rotation will not affect the system. 1. NOTE: Click here to view an animated version of this procedure. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. ^ The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the activation tool must remain in place 180 degrees from the valve stem. Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the special tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the VSM. Click here to view an animated version of this procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 6310 7. Within 2 minutes of the horn sounding, place the activation tool on the RF tire sidewall opposite (180°) from the valve stem to train the RF tire pressure sensor. 8. NOTE: Do not wait more than 2 minutes between training each sensor or the VSM will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor IDs trained to the VSM and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the VSM to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed VSM. If the sensors are being trained due to the installation of a new VSM, clear any DTCs and perform the VSM on-demand self test. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 6311 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool against the LF tire sidewall 180 degrees from the tire valve stem. 3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the activation tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. 1. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. Click here to view an animated version of this procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6314 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. Click here to view an animated version of this procedure. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor may occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6315 3. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6316 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6317 Part 1 Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter, but all strap kits share the same base part number. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. Remove a factory installed strap in the following sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item on both sides of the buckle approximately 25 mm (0.98 in) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. 3. To remove a dealer-installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 4. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Click here to view an animated version of this procedure. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers may damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6318 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180 degrees from the valve stem. Click here to view a video version of this procedure. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. Click here to view an animated version of this procedure. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 in) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6319 6. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages Low Tire Pressure Indicator: Testing and Inspection Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages > Page 6325 Low Tire Pressure Indicator: Testing and Inspection Tire Pressure Monitoring System (TPMS) Indicator Illuminates Continuously Tire Pressure Monitoring System (TPMS) Indicator Illuminates Continuously NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPMS functionality before carrying out any diagnosis. NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressures for front and rear tires, tire rotation will not affect the system. 1. The TPMS indicator remains on continuously for the following condition: ^ Low Tire Pressure - The TPMS indicator is illuminated solid and the message center displays LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low. When this condition exists, the tire pressure must be adjusted to the recommended cold pressure as indicated on the vehicle certification label. 2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been stationary for more than 30 minutes, it will be necessary to wake up the sensors so they will transmit the latest tire pressure information to the VSM. If the vehicle has been stationary for more than 30 minutes, refer to the Tire Pressure Monitoring System (TPMS) Sensor Activation procedure. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages > Page 6326 Low Tire Pressure Indicator: Testing and Inspection Tire Pressure Monitoring System (TPMS) Indicator Flashes Tire Pressure Monitoring System (TPMS) Indicator Flashes The TPMS indicator flashes for 70 seconds and then remains ON solid when the ignition key is turned to the ON position for the following conditions: 1. Tire Pressure Sensor Fault - If equipped, the message center will display TIRE SENSOR FAULT when a tire pressure sensor is malfunctioning. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 2. No communication with the VSM (TPMS is integral to the VSM) - The TPMS indicator is illuminated when the instrument cluster has received no signals from the VSM for more than 5 seconds. If equipped, the message center displays TIRE MONITOR FAULT. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE MONITOR FAULT when the tire pressure monitoring system is malfunctioning or communication with the instrument cluster has been lost. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Locations Tire Pressure Module: Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Locations > Page 6330 View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Locations > Page 6331 Tire Pressure Module: Diagrams C3008A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Locations > Page 6332 C3008B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the vehicle security module (VSM). Refer to Tire Pressure Monitoring System (TPMS) Sensor Activation. See: Testing and Inspection/Programming and Relearning NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with tire pressure monitor system (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the activation tool, attempt to activate the same sensor with the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least 1/4 of a turn and attempt to activate the same sensor again. NOTE: The VSM has a 2 minute time limit between sensor responses. If the VSM does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the tire pressure must be adjusted and the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressures for front and rear tires, tire rotation will not affect the system. 1. NOTE: Click here to view an animated version of this procedure. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. ^ The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the activation tool must remain in place 180 degrees from the valve stem. Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the special tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the VSM. Click here to view an animated version of this procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 6337 7. Within 2 minutes of the horn sounding, place the activation tool on the RF tire sidewall opposite (180°) from the valve stem to train the RF tire pressure sensor. 8. NOTE: Do not wait more than 2 minutes between training each sensor or the VSM will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor IDs trained to the VSM and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the VSM to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed VSM. If the sensors are being trained due to the installation of a new VSM, clear any DTCs and perform the VSM on-demand self test. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 6338 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool against the LF tire sidewall 180 degrees from the tire valve stem. 3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the activation tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. 1. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. Click here to view an animated version of this procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6341 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. Click here to view an animated version of this procedure. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor may occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6342 3. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6343 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6344 Part 1 Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter, but all strap kits share the same base part number. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. Remove a factory installed strap in the following sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item on both sides of the buckle approximately 25 mm (0.98 in) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. 3. To remove a dealer-installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 4. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Click here to view an animated version of this procedure. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers may damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6345 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180 degrees from the valve stem. Click here to view a video version of this procedure. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. Click here to view an animated version of this procedure. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 in) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6346 6. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair Tires: Service and Repair Tire Rotation Rotating your tires at the recommended interval (as indicated in the Scheduled Maintenance Guide that comes with your vehicle) will help your tires wear more evenly, provided better tire performance and longer tire life. Sometimes irregular tire wear ran be corrected by rotating the tires. Note: If your tires show uneven wear ask an authorized dealer to check for and correct any wheel misalignment, tire imbalance or mechanical problem involved before tire rotation. Note: Your vehicle may be equipped with a dissimilar spare tire/wheel. A dissimilar spare tire/wheel is defined as a spare tire and/or wheel that is different in brand, site or appearance from the road tires and wheels. If you have a dissimilar spare tire/wheel it is intended for temporary use only and should not be used in a tire rotation. Note: After having your tires rotated, inflation pressure must be checked and adjusted to the vehicle requirements. If the tire label shows different tire pressures for the front and rear tires and the vehicle is equipped with TPMS (tire pressure monitoring system), Always perform the TPMS reset procedure after tire rotation. If the system is not reset, it may not provide a low tire pressure warning when necessary. See: Tire Monitoring System/Low Tire Pressure Indicator Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications SPINDLE BEARING LUBRICANT Premium Long-Life Grease Ford Part Number ..................................................................................................................................... XG-1-C or XG-1-K (US); CXG-1-C (Canada) Ford Specification .......................................................................... ............................................................................................................ ESA-M1C75-B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Wheel Bearing and Wheel Hub Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used during reassembly to make sure correct retention of these parts. 1. Remove the wheel and tire. 2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the 2 bolts and position the caliper and anchor plate assembly aside. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 200 Nm (148 lb-ft). 3. Remove the cotter pin and wheel hub nut retainer. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6355 ^ Discard the cotter pin. 4. Remove and discard the wheel hub nut. ^ To install, tighten to 400 Nm (296 lb-ft). 5. Remove the brake disc/wheel bearing and wheel hub assembly. 6. CAUTION: Do not apply lubricant to the threaded end of the wheel spindle or incorrect clamp load may occur. NOTE: Clean the wheel spindle (including the threaded end) of any dirt or grease using the specified solvent before installing the brake disc. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6356 Wheel Bearing: Service and Repair Rear Ford 8.8-Inch Ring Gear Rear Wheel Bearing and Axle Shaft Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6357 Removal 1. Remove the axle shaft. 2. NOTE: If the axle shaft oil seal is leaking, the axle housing vent may be plugged with foreign material. NOTE: Use care to avoid damaging the axle shaft oil seal bore. Using a suitable seal remover, remove and discard the axle shaft oil seal. 3. Inspect the rear wheel bearing and axle shaft for wear or damage. 4. If necessary, using the special tools, remove the rear wheel bearing. Installation 1. If removed, lubricate the new rear wheel bearing with axle lubricant. 2. If removed, use the special tools to install the rear wheel bearing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6358 3. Lubricate the lip of the new axle shaft oil seal with grease. 4. Using the special tools, install the new axle shaft oil seal. 5. Install the axle shaft. Ford 9.75-Inch Ring Gear Rear Wheel Bearing and Axle Shaft Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6359 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6360 Removal 1. Remove the axle shaft. 2. NOTE: If only a new axle shaft oil seal needs to be installed, use care to avoid damaging the axle shaft oil seal bore. Using a suitable seal remover, remove and discard the axle shaft oil seal. 3. Inspect the rear wheel bearing and axle shaft for wear or damage. 4. Using the special tools, remove the rear wheel bearing. Installation 1. Lubricate the new rear wheel bearing with axle lubricant. 2. Using the special tools, install the rear wheel bearing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6361 3. Lubricate the lip of the new axle shaft oil seal with grease. 4. Using the special tools, install the new axle shaft oil seal. 5. Install the axle shaft. Ford 10.25-Inch Ring Gear Rear Wheel Bearing and Axle Shaft Seal Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6362 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6363 Removal 1. Remove the axle shaft. 2. NOTE: If only a new axle shaft oil seal needs to be installed, use care to avoid damaging the axle shaft oil seal bore. Using a suitable seal remover, remove and discard the axle shaft oil seal. 3. Inspect the rear wheel bearing and axle shaft for wear or damage. 4. Using the special tools, remove the rear wheel bearing. Installation 1. Lubricate the new rear wheel bearing with axle lubricant. 2. Using the special tools, install the rear wheel bearing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6364 3. Lubricate the lip of the new axle shaft oil seal with grease. 4. Using the special tools, install the new axle shaft oil seal. 5. Install the axle shaft. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations View 151-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 6369 C1291 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Nuts (With Vehicle Weight On Wheels) ..................................................................................................................... Tighten to 204 Nm (150 lb-ft) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation Accumulator HVAC: Description and Operation SUCTION ACCUMULATOR NOTE: Installation of a new suction accumulator is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. Damage to the suction accumulator includes leaks in the suction accumulator, physical damage to the suction accumulator shell or desiccant, or moisture contamination. Moisture contamination results only from a complete loss of refrigerant and equalization of the refrigerant system pressure with atmospheric pressure for a period longer than one hour. If even a slight amount of positive refrigerant pressure is present in the system before repairs are carried out, the suction accumulator should not be replaced. The suction accumulator is mounted at the RH rear of the engine compartment. The evaporator outlet line attaches directly to the inlet of the suction accumulator and the compressor manifold and tube assembly attaches to the suction accumulator outlet. After entering the inlet of the suction accumulator, the heavier oil-laden refrigerant contacts an internally mounted dome (which serves as an umbrella) and drips down onto the bottom of the canister. - A small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. - As the heavier mixture passes through the small diameter liquid bleed hole, it has a second chance to vaporize and recirculate through the A/C compressor without causing compressor damage due to slugging. - A fine mesh screened filter fits tightly around the bottom of the vapor return inlet to filter out refrigerant system contaminant particles. - A desiccant bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation > Page 6377 Accumulator HVAC: Service and Repair SUCTION ACCUMULATOR Removal and Installation NOTE: - Installation of a new suction accumulator is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. Damage to the suction accumulator includes leaks in the suction accumulator, physical damage to the suction accumulator shell or desiccant, or moisture contamination. Moisture contamination results only from a complete loss of refrigerant and equalization of the refrigerant system pressure with atmospheric pressure for a period longer than one hour. If even a slight amount of positive refrigerant pressure is present in the system before repairs are carried out, the suction accumulator should not be replaced. - Care should be taken to minimize exposure of the suction accumulator desiccant to the atmosphere. Do not remove the shipping caps from the new suction accumulator until immediately before the line fittings are to be attached. Evacuation of the refrigerant system must be started as soon as the new suction accumulator is installed. 1. Recover the refrigerant. 2. Remove the PCM. 3. Remove the battery and battery tray. 4. Remove the PCM bracket. 1 Remove the 3 PCM bracket bolts. 2 Remove the PCM bracket. - To install, tighten to 10 Nm (89 lb-in). 5. Remove the suction accumulator outlet fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation > Page 6378 6. Disconnect the suction accumulator inlet fitting. - Discard the O-ring seals. 7. Remove the 2 suction accumulator bracket nuts. - To install, tighten to 9 Nm (80 lb-in). 8. Remove the suction accumulator. 9. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 10. Evacuate, leak test and charge the refrigerant system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Locations View 151-20 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 08-23-6 > Nov > 08 > A/C Cannot Control Output Temperature Air Door Actuator / Motor: Customer Interest A/C - Cannot Control Output Temperature TSB 08-23-6 11/24/08 EATC - INTERMITTENT WARM AIR OUTPUT TEMPERATURE SET 68-72 F (18-22 C) EMTC - INABILITY TO CONTROL TEMPERATURE OUTPUT FORD: 2005-2008 F-15O LINCOLN: 2006-2008 Mark LT ISSUE Some 2005-2008 F-150 and 2006-2008 Mark LT vehicles equipped with Electronic Automatic Temperature Control (EATC) may exhibit intermittent periods of warm air output in Auto mode with the temperature control set between 68-72 degrees Fahrenheit (18-22 degrees Celsius). Some 2005-2008 F-150 vehicles equipped with Electronic Manual Temperature Control (EMTC) may exhibit periods where the cabin temperature cannot be maintained with the control knob. Some customers may also complain the heat cannot be reduced without rotating the control knob well into the Cool/Blue range. ACTION Refer to the following Service Procedure to correct the condition. SERVICE PROCEDURE The condition may be caused by a faulty temperature blend door actuator. 1. Check actuator activity. a. EATC systems may be monitored with the IDS PID (LBLNDPOS). b. EMIC systems may be observed through the right side of the instrument panel with the glove compartment door positioned downward. 2. Erratic PID activity or an actuator that appears to be erratically hunting for correct position during the condition should be replaced. Refer to Workshop Manual, Section 412-01,for removal and installation details. NOTE THE IGNITION KEY MUST BE OFF WHEN REPLACING THE ACTUATOR. ENERGIZING THE ACTUATOR BEFORE INSTALLATION ON THE HEATING VENTILATION AIR CONDITIONING (HVAC) CASE WILL CAUSE THE PART TO BECOME MISS POSITIONED AND CORRECT ORIENTATION WILL BE LOST. INCORRECT ACTUATOR OPERATION MAY RESULT. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082306A 2005-2007 F-150, 0.7 Hr. 2006-2007 Mark LT: Replace The Temperature Blend Door Actuator. (Do Not Use With 19700D, 19700D6, 19616C, 12650D) 082306A 2008 F-150, 2008 Mark 0.5 Hr. LT: Replace The Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 08-23-6 > Nov > 08 > A/C Cannot Control Output Temperature > Page 6391 Temperature Blend Door Actuator. (Do Not Use With 19700D, 19700D6, 19616C, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 19E6i6 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 08-8-9 > Apr > 08 > A/C Grinding Noise When Changing Modes Air Door Actuator / Motor: Customer Interest A/C - Grinding Noise When Changing Modes TSB 08-8-9 04/28/08 GRINDING NOISE FROM CLIMATE CONTROL - CHANGING AIR DISTRIBUTION MODES BUILT AFTER 11/29/2005 FORD: 2005-2008 F-150 LINCOLN: 2006-2008 Mark LT ISSUE Some 2005-2008 F-150 (excludes Heritage) and 2006-2008 Lincoln Mark LT vehicles built after 11/29/2005 may exhibit a grinding noise from the climate control system while changing air distribution modes. ACTION Perform the following Service Procedure to correct the condition. SERVICE PROCEDURE 1. Set control head to panel mode. NOTE DO NOT ENERGIZE THE MODE DOOR MOTOR WITHOUT IT BEING CONNECTED TO THE UPPER PLENUM. 2. Leaving the motor plugged in and installed to the cam plate, remove the four bolts that attach the cam plate to the upper plenum. (Figure 1) 3. Remove cam plate. 4. Remove cam. 5. Clean all existing lube from cam. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 08-8-9 > Apr > 08 > A/C Grinding Noise When Changing Modes > Page 6396 6. Liberally apply Motorcraft(R) PTFE Lubricant to the cam tracks. (Figure 2) 7. Reassemble components in reverse order of removal. 8. Cycle the control head from panel to defrost mode a few times until the noise is eliminated. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 080809A 2005-2008 F-150, 0.4 Hr. 2006-2008 Mark LT: Remove Distribution Mode Door Cam and Replace Cam Lubricant. DEALER CODING CONDITION BASIC PART NO. CODE 18471 41 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 08-23-6 > Nov > 08 > A/C - Cannot Control Output Temperature Air Door Actuator / Motor: All Technical Service Bulletins A/C - Cannot Control Output Temperature TSB 08-23-6 11/24/08 EATC - INTERMITTENT WARM AIR OUTPUT TEMPERATURE SET 68-72 F (18-22 C) EMTC - INABILITY TO CONTROL TEMPERATURE OUTPUT FORD: 2005-2008 F-15O LINCOLN: 2006-2008 Mark LT ISSUE Some 2005-2008 F-150 and 2006-2008 Mark LT vehicles equipped with Electronic Automatic Temperature Control (EATC) may exhibit intermittent periods of warm air output in Auto mode with the temperature control set between 68-72 degrees Fahrenheit (18-22 degrees Celsius). Some 2005-2008 F-150 vehicles equipped with Electronic Manual Temperature Control (EMTC) may exhibit periods where the cabin temperature cannot be maintained with the control knob. Some customers may also complain the heat cannot be reduced without rotating the control knob well into the Cool/Blue range. ACTION Refer to the following Service Procedure to correct the condition. SERVICE PROCEDURE The condition may be caused by a faulty temperature blend door actuator. 1. Check actuator activity. a. EATC systems may be monitored with the IDS PID (LBLNDPOS). b. EMIC systems may be observed through the right side of the instrument panel with the glove compartment door positioned downward. 2. Erratic PID activity or an actuator that appears to be erratically hunting for correct position during the condition should be replaced. Refer to Workshop Manual, Section 412-01,for removal and installation details. NOTE THE IGNITION KEY MUST BE OFF WHEN REPLACING THE ACTUATOR. ENERGIZING THE ACTUATOR BEFORE INSTALLATION ON THE HEATING VENTILATION AIR CONDITIONING (HVAC) CASE WILL CAUSE THE PART TO BECOME MISS POSITIONED AND CORRECT ORIENTATION WILL BE LOST. INCORRECT ACTUATOR OPERATION MAY RESULT. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082306A 2005-2007 F-150, 0.7 Hr. 2006-2007 Mark LT: Replace The Temperature Blend Door Actuator. (Do Not Use With 19700D, 19700D6, 19616C, 12650D) 082306A 2008 F-150, 2008 Mark 0.5 Hr. LT: Replace The Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 08-23-6 > Nov > 08 > A/C - Cannot Control Output Temperature > Page 6402 Temperature Blend Door Actuator. (Do Not Use With 19700D, 19700D6, 19616C, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 19E6i6 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 08-8-9 > Apr > 08 > A/C - Grinding Noise When Changing Modes Air Door Actuator / Motor: All Technical Service Bulletins A/C - Grinding Noise When Changing Modes TSB 08-8-9 04/28/08 GRINDING NOISE FROM CLIMATE CONTROL - CHANGING AIR DISTRIBUTION MODES BUILT AFTER 11/29/2005 FORD: 2005-2008 F-150 LINCOLN: 2006-2008 Mark LT ISSUE Some 2005-2008 F-150 (excludes Heritage) and 2006-2008 Lincoln Mark LT vehicles built after 11/29/2005 may exhibit a grinding noise from the climate control system while changing air distribution modes. ACTION Perform the following Service Procedure to correct the condition. SERVICE PROCEDURE 1. Set control head to panel mode. NOTE DO NOT ENERGIZE THE MODE DOOR MOTOR WITHOUT IT BEING CONNECTED TO THE UPPER PLENUM. 2. Leaving the motor plugged in and installed to the cam plate, remove the four bolts that attach the cam plate to the upper plenum. (Figure 1) 3. Remove cam plate. 4. Remove cam. 5. Clean all existing lube from cam. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 08-8-9 > Apr > 08 > A/C - Grinding Noise When Changing Modes > Page 6407 6. Liberally apply Motorcraft(R) PTFE Lubricant to the cam tracks. (Figure 2) 7. Reassemble components in reverse order of removal. 8. Cycle the control head from panel to defrost mode a few times until the noise is eliminated. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 080809A 2005-2008 F-150, 0.4 Hr. 2006-2008 Mark LT: Remove Distribution Mode Door Cam and Replace Cam Lubricant. DEALER CODING CONDITION BASIC PART NO. CODE 18471 41 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Air Inlet Mode Door Actuator View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Air Inlet Mode Door Actuator > Page 6410 View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Air Inlet Mode Door Actuator > Page 6411 View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Air Inlet Mode Door Actuator C289 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Air Inlet Mode Door Actuator > Page 6414 C236 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Air Inlet Mode Door Actuator > Page 6415 C2092 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator Air Door Actuator / Motor: Service and Repair Mode Door Actuator Air Inlet Door MODE DOOR ACTUATOR - AIR INLET DOOR Removal and Installation 1. Remove the instrument panel. 2. Disconnect the air inlet mode door actuator electrical connector. 3. Remove the 3 air inlet mode door actuator screws. 4. Remove the air inlet door mode door actuator. 5. To install, reverse the removal procedure. Defrost/Panel/Floor Door MODE DOOR ACTUATOR - DEFROST/PANEL/FLOOR DOOR Removal and Installation Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator > Page 6418 1. NOTE: The defrost/panel/floor mode door actuator can be accessed from underneath the LH side of the instrument panel. Disconnect the defrost/panel/floor mode door actuator electrical connector. 2. Remove the 3 defrost/panel/floor mode door actuator screws. 3. Remove the defrost/panel/floor mode door actuator. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Mode Door Actuator > Page 6419 Air Door Actuator / Motor: Service and Repair Temperature Blend Door Actuator TEMPERATURE BLEND DOOR ACTUATOR Removal and Installation 1. Remove the audio control module (ACM). 2. While pushing the glove compartment door tab, position the glove compartment downward. 3. Remove the 3 temperature blend door actuator screws. 4. Detach the temperature blend door actuator. 5. Disconnect the temperature blend door actuator electrical connector. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations View 151-2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6423 C132 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6424 In-Vehicle Temperature Sensor - HVAC Module - Electronic Automatic Temperature Control (EATC) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6430 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6431 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6432 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6433 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6434 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6435 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6436 Blower Motor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6437 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6438 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6439 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6440 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6441 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6442 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6443 C2004 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 6444 Blower Motor: Service and Repair BLOWER MOTOR Removal and Installation 1. Remove the RH lower A-pillar trim panel. 2. Position aside the carpet below the blower motor. 3. Disconnect the blower motor electrical connector. 4. Remove the 3 blower motor screws. 5. Remove the blower motor. 6. Remove the blower motor wheel. 1 Remove the blower motor wheel clip. 2 Remove the blower motor wheel. 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 6448 Blower Motor Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 6449 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations View 151-18 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 6453 C2185 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 6454 Blower Motor Resistor: Description and Operation BLOWER MOTOR RESISTOR The blower motor resistor adjusts the blower motor speed based on the blower motor switch setting. The blower motor resistor contains 3 resistor coils in series. The end of each resistor coil is wired to a setting in the blower motor switch. Voltage from the blower motor relay is available at the blower motor at all times when the blower selector is in an ON position, and then continues to the blower motor resistor. The blower motor switch will allow a path to ground with the addition of 1, 2 or 3 coils in the blower motor resistor to the circuit. When the blower motor switch is in the MED HI position, the blower motor switch will add a path to ground through one coil in the blower motor resistor. When the blower motor switch is in the MED LO position, the blower motor switch will add a path to ground through 2 coils (in series) in the blower motor resistor. When the blower motor switch is in the LO position, the blower motor switch will add a path to ground through 3 coils (in series) in the blower motor resistor. When the blower motor switch is in the HI position, the blower motor resistor is bypassed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 6455 Blower Motor Resistor Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 6456 Blower Motor Resistor: Service and Repair BLOWER MOTOR RESISTOR Removal and Installation 1. NOTE: The blower motor resistor can be accessed from below the RH side of the instrument panel. Disconnect the blower motor resistor electrical connector. 2. Remove the 2 blower motor resistor screws. 3. Remove the blower motor resistor. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations View 151-18 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 6460 C271 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 6461 Blower Motor Switch: Description and Operation BLOWER MOTOR SWITCH The blower motor switch is mounted in the HVAC module and controls blower motor speed by adding or bypassing resistors in the blower motor resistor in all function selector switch positions except OFF. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 6462 Blower Motor Switch: Service and Repair BLOWER MOTOR SPEED CONTROL Removal and Installation 1. NOTE: The blower motor speed control can be accessed from below the RH side of the instrument panel. Disconnect the blower motor speed control electrical connector. 2. Remove the blower motor speed control screw. 3. Detach the blower motor speed control. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair This vehicle is not equipped with a cabin air filter. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 6469 C233 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 6470 Cabin Temperature Sensor / Switch: Service and Repair IN-VEHICLE TEMPERATURE SENSOR Removal and Installation 1. Remove the instrument cluster finish panel. 2. Remove the 2 in-vehicle temperature sensor screws. 3. Remove the temperature sensor finish panel. 4. Remove the in-vehicle temperature sensor. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Item....................................................................................................................................................... ..............................................................Specification A/C Compressor Magnetic Clutch Air gap clearance.................................................................................................................................. ...................................0.35-0.65 mm (0.014-0.026 in) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6475 Compressor Clutch: Adjustments AIR CONDITIONING (A/C) CLUTCH AIR GAP ADJUSTMENT 1. Check the A/C clutch air gap at 3 equally spaced places between the clutch plate and the A/C clutch pulley. 2. Remove the clutch plate. Add or remove spacers between the clutch plate hub and the compressor shaft until the clearance is within specification. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams C1110 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6479 Compressor Clutch Coil: Service and Repair CLUTCH AND CLUTCH FIELD COIL Special Tool(s) Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6480 Removal 1. Remove the A/C compressor. 2. Remove the A/C clutch disc and hub bolt. 1 Using the special tool, hold the A/C clutch disc and hub. 2 Remove the A/C clutch disc and hub bolt. 3. Remove the A/C clutch disc and hub. 4. Remove the A/C compressor pulley snap ring. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6481 5. CAUTION: Do not use air tools. Damage to the air conditioning (A/C) clutch pulley or A/C compressor may result. Using the special tool, remove the A/C compressor pulley. 1 Install the special tool. 2 Remove the A/C compressor pulley. 6. Remove the A/C clutch field coil snap ring. 7. Remove the A/C clutch field coil electrical connector screw. 8. Remove the A/C clutch field coil. Installation NOTE: The A/C clutch components should be reused unless obvious signs of damage are found. If excessive grooving is found, a new A/C clutch disc and hub and a new A/C compressor pulley must be installed together. Otherwise, each component can be installed individually where needed. 1. Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage. - Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat. - Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor pulley that is more than fingernail depth. - Inspect for roughness in the A/C compressor pulley bearing. 2. Clean the A/C clutch field coil and pulley mounting surfaces. 3. Install the A/C clutch field coil. 4. Install the A/C clutch field coil electrical connector screw. 5. Install the A/C clutch field coil snap ring. 6. NOTE: The A/C compressor pulley is a tight fit on the A/C compressor. It must be correctly aligned during installation. Install the A/C compressor pulley. 7. Install the A/C compressor pulley snap ring with the bevel side out. 8. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening. 9. Install the A/C clutch disc and hub. 10. Using the special tool, install the A/C compressor clutch disc and hub bolt. 1 Hold the A/C clutch disc and hub with the special tool. 2 Tighten the bolt to 14 Nm (10 lb-ft). 11. Measure and adjust the clutch air gap by removing or adding A/C clutch disc and hub spacers. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 6482 12. Install the A/C compressor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Technical Service Bulletins > Customer Interest for Compressor Pulley: > 07-24-7 > Dec > 07 > A/C Compressor Shuts OFF in High Temperatures Compressor Pulley: Customer Interest A/C - Compressor Shuts OFF in High Temperatures TSB 07-24-7 12/10/07 A/C COMPRESSOR SHUTOFF - HIGH AMBIENT TEMPERATURES - VEHICLE STATIONARY IN GEAR FORD: 2007-2008 F-150, F-150 LINCOLN: 2007-2008 Mark LT ISSUE Some 2007-2008 Mark LT and F-150 vehicles equipped with 5.4L or 4.6L engine only, may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C), when the vehicle is stationary for periods longer than 15 minutes, with the transmission in gear. Idling in gear and extreme ambient temperatures may cause the vehicle control systems to disable A/C compressor operation. ACTION Follow the Service Procedure steps to replace the A/C compressor pulley and coolant pump pulley. SERVICE PROCEDURE NOTE THIS TSB IS INTENDED TO RESTORE A/C COMPRESSOR OPERATION IN EXTREME HIGH AMBIENT TEMPERATURES WHEN THE TRANSMISSION IS PLACED IN THE PARK POSITION. DO NOT ATTEMPT TO ADDRESS CUSTOMER CONCERNS OF GENERAL A/C TEMPERATURE OUTPUT PERFORMANCE WITH THIS TSB. THIS TSB WILL NOT IMPROVE A/C SYSTEM DUCT TEMPERATURE OUTPUT PERFORMANCE. NOTE DURING EXTREME HIGH AMBIENT TEMPERATURES WHEN IDLING STATIONARY FOR EXTENDED PERIODS OF TIME IN GEAR, IT IS RECOMMENDED TO OPERATE THE A/C IN THE MAX POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, AND PUT THE TRANSMISSION INTO THE PARK POSITION TO CONTINUE TO RECEIVE COOL AIR FROM THE A/C SYSTEM. 1. Replace the A/C compressor pulley. Follow Workshop Manual (WSM), Section 412-01 for removal and installation details. 2. Replace the coolant pump pulley. Follow WSM, Section 303-03 for removal and installation details. 3. Drain approximately 1 quart of coolant from the cooling system into a clean container which will permit reuse of coolant in the vehicle. Refer to WSM, Section 303-03. 4. Replace the clamp on the heater core feed hose, near the right hand front of engine, at the water pump outlet pipe connection point. 5. Refill the cooling system. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072407A 2007-2008 F-150 4X2, 1.7 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X2. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Technical Service Bulletins > Customer Interest for Compressor Pulley: > 07-24-7 > Dec > 07 > A/C Compressor Shuts OFF in High Temperatures > Page 6491 8509A,8620F, 8616A, 18472A). 072407B 2007-2008 F-150 4X4, 1.9 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X4. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, 8509A,8620F, 8616A, 18472A). DEALER CODING CONDITION BASIC PART NO. CODE 8A616 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Pulley: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures Compressor Pulley: All Technical Service Bulletins A/C - Compressor Shuts OFF in High Temperatures TSB 07-24-7 12/10/07 A/C COMPRESSOR SHUTOFF - HIGH AMBIENT TEMPERATURES - VEHICLE STATIONARY IN GEAR FORD: 2007-2008 F-150, F-150 LINCOLN: 2007-2008 Mark LT ISSUE Some 2007-2008 Mark LT and F-150 vehicles equipped with 5.4L or 4.6L engine only, may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C), when the vehicle is stationary for periods longer than 15 minutes, with the transmission in gear. Idling in gear and extreme ambient temperatures may cause the vehicle control systems to disable A/C compressor operation. ACTION Follow the Service Procedure steps to replace the A/C compressor pulley and coolant pump pulley. SERVICE PROCEDURE NOTE THIS TSB IS INTENDED TO RESTORE A/C COMPRESSOR OPERATION IN EXTREME HIGH AMBIENT TEMPERATURES WHEN THE TRANSMISSION IS PLACED IN THE PARK POSITION. DO NOT ATTEMPT TO ADDRESS CUSTOMER CONCERNS OF GENERAL A/C TEMPERATURE OUTPUT PERFORMANCE WITH THIS TSB. THIS TSB WILL NOT IMPROVE A/C SYSTEM DUCT TEMPERATURE OUTPUT PERFORMANCE. NOTE DURING EXTREME HIGH AMBIENT TEMPERATURES WHEN IDLING STATIONARY FOR EXTENDED PERIODS OF TIME IN GEAR, IT IS RECOMMENDED TO OPERATE THE A/C IN THE MAX POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, AND PUT THE TRANSMISSION INTO THE PARK POSITION TO CONTINUE TO RECEIVE COOL AIR FROM THE A/C SYSTEM. 1. Replace the A/C compressor pulley. Follow Workshop Manual (WSM), Section 412-01 for removal and installation details. 2. Replace the coolant pump pulley. Follow WSM, Section 303-03 for removal and installation details. 3. Drain approximately 1 quart of coolant from the cooling system into a clean container which will permit reuse of coolant in the vehicle. Refer to WSM, Section 303-03. 4. Replace the clamp on the heater core feed hose, near the right hand front of engine, at the water pump outlet pipe connection point. 5. Refill the cooling system. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072407A 2007-2008 F-150 4X2, 1.7 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X2. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Pulley: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures > Page 6497 8509A,8620F, 8616A, 18472A). 072407B 2007-2008 F-150 4X4, 1.9 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X4. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, 8509A,8620F, 8616A, 18472A). DEALER CODING CONDITION BASIC PART NO. CODE 8A616 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6501 Compressor Clutch Relay: Description and Operation AIR CONDITIONING (A/C) CLUTCH RELAY (A/CCR) NOTE: The PCM PIDs WAC and wide open throttle air conditioning cutoff fault (WACF) are used to monitor the A/CCR output. The A/CCR is wired normally open. There is no direct electrical connection between the A/C switch or electronic automatic temperature control (EATC) module and the A/C clutch. The PCM receives a signal indicating that A/C is requested. For some applications, this message is sent through the communications network. When A/C is requested, the PCM checks other A/C related inputs that are available, such as A/C pressure switch and A/C cycling switch. If these inputs indicate A/C operation is OK, and the engine conditions are OK (coolant temperature, engine RPM, throttle position), the PCM grounds the A/CCR output, closing the relay contacts and sending voltage to the A/CCR. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > 4x4 Relay Box Compressor Clutch Relay: Testing and Inspection 4x4 Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > 4x4 Relay Box > Page 6504 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > 4x4 Relay Box > Page 6505 Compressor Clutch Relay: Testing and Inspection 4x2 Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > 4x4 Relay Box > Page 6506 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation Condenser HVAC: Description and Operation CONDENSER CORE The condenser core has the following characteristics: - It is an aluminum fin and tube design heat exchanger located in front of the vehicle radiator - It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat and by condensing gas to liquid refrigerant as it is cooled Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 6510 Condenser HVAC: Service and Repair CONDENSER CORE Removal and Installation 1. Recover the refrigerant. 2. Remove the upper radiator sight shield. 3. Disconnect the condenser fittings. - Discard the O-ring seals. - To install, tighten to 25 Nm (18 lb-ft). 4. Position the transmission oil cooler aside. - Remove the 2 transmission oil cooler bolts. - Position the transmission oil cooler aside. To install, tighten to 12 Nm (9 lb-ft). 5. Position the hood latch bracket aside. - Remove the 3 hood latch bracket bolts. - Position the hood latch bracket aside. To install, tighten to 12 Nm (9 lb-ft). 6. Remove the 2 condenser bracket bolts. - To install, tighten to 18 Nm (13 lb-ft). 7. Remove the condenser core. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 6511 8. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 9. Evacuate, leak test and charge the refrigerant system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions Control Assembly: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6516 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6517 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6518 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6519 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6520 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6521 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6522 Control Assembly: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6523 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6524 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6525 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6526 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6527 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6528 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 6529 Control Assembly: Service and Repair HEATING VENTILATION AIR CONDITIONING (HVAC) MODULE Removal and Installation 1. Remove the center instrument panel finish panel. 2. Remove the 4 HVAC module screws. 3. Remove the HVAC module. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > HVAC Module, EATC View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > HVAC Module, EATC > Page 6534 View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > HVAC Module, EATC Control Module HVAC: Diagrams HVAC Module, EATC C228A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > HVAC Module, EATC > Page 6537 C228B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > HVAC Module, EATC > Page 6538 Control Module HVAC: Diagrams HVAC Module, EMTC C294A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > HVAC Module, EATC > Page 6539 C294B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation Coupler HVAC: Description and Operation SPRING LOCK COUPLING Spring Lock Coupling When disconnecting or connecting spring lock couplings, observe the following. - When the coupling is connected together, 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. - Three O-ring seals are used to seal between the 2 halves of the couplings. - Use only the O-ring seals listed in the Ford Master Parts Catalog for the spring lock coupling. - A plastic indicator ring is used to indicate, during vehicle assembly, that the coupling is connected. Once the coupling is connected, the indicator ring is no longer necessary but will remain captive by the coupling near the cage opening. - The indicator ring may also be used during service operations to indicate connection of the coupling. - An A/C tube lock coupling clip may be used to secure the coupling but is not required. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Coupler HVAC: Service and Repair Spring Lock Coupling SPRING LOCK COUPLING Special Tool(s) Special Tool(s) Disconnect 1. Remove the spring lock coupling clip, if equipped. 2. CAUTION: Do not use metal tools to remove the O-ring seals. They may cause axial scratches across the O-ring seal grooves, resulting in refrigerant leaks. Push the Refrigerant Coupling Spring Remover into the cage opening to release the female fitting from the spring lock coupling spring and pull the fitting apart. Remove the O-ring seals using a non-metallic tool. 3. CAUTION: Do not use a screwdriver or similar tool to remove the air conditioning (A/C) tube lock coupling spring; this may cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. Remove the spring lock coupling spring with a small hooked wire. Connect 1. Install the spring lock coupling spring. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 6545 2. Lubricate the inside of the coupling with PAG oil. 3. CAUTION: Use only the new O-ring seals. The use of any O-ring seals other than those specified in the Ford Master Parts Catalog may result in intermittent leakage during vehicle operation. Install the O-ring seals. 4. Connect the spring lock coupling fittings with a twisting motion until the spring lock coupling spring snaps over the flared end of the female fitting. 5. Install the spring lock coupling clip. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 6546 Coupler HVAC: Service and Repair Air Conditioning Line (Peanut) Fitting AIR CONDITIONING LINE (PEANUT) FITTING Disconnect 1. CAUTION: Support the female fitting with a wrench to prevent the tubes from twisting. Remove the nut and separate the 2 halves of the peanut fitting. 2. CAUTION: Do not use metal tools to remove the O-ring seal. They can cause axial scratches across the O-ring seal groove, resulting in refrigerant leaks. Remove the O-ring seal with a non-metallic tool. Connect 1. Clean all dirt or foreign material from the fittings. 2. CAUTION: Use only the new O-ring seals. The use of any O-ring seals other than those specified in the Ford Master Parts Catalog may result in intermittent leakage during vehicle operation. Install the O-ring seal. 3. NOTE: When correctly assembled, the male and female fittings should be flush. Assemble the male and female fittings together. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 6547 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation Evaporator Core: Description and Operation EVAPORATOR CORE NOTE: If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. The evaporator core is a plate/fin type. - A mixture of refrigerant and oil enters the bottom of the evaporator core through the evaporator core inlet tube and then moves out of the evaporator core through the evaporator core outlet tube. - Airflow from the blower motor passes through the evaporator core where it is cooled and dehumidified before entering the passenger compartment. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 6551 Evaporator Core: Testing and Inspection A/C EVAPORATOR/CONDENSER CORE - ON VEHICLE LEAK TEST 1. Recover the refrigerant. Refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging. 2. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. 3. Clean the spring lock couplings. Refer to Spring Lock Coupling. 4. Connect the appropriate test fittings from the R-12/R-134a Air Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make 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 shut-off valve does not open. Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low-pressure gauge reading will not drop to 101 kPa (30 in-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 installing a new A/C evaporator core or A/C condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. If the low-pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) 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 gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. - If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss. 9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 6552 Evaporator Core: Service and Repair EVAPORATOR CORE Removal and Installation NOTE: If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. 1. Remove the heater core. 2. Remove the screws and detach the wire harness from the evaporator core cover. 3. Remove the screws and the blower motor resistor (electronic manual temperature control [EMTC]) or blower motor speed control (electronic automatic temperature control [EATC]). 4. Remove the bottom evaporator core cover screws. 5. Disconnect the air inlet mode door actuator electrical connector. 6. Disconnect the air inlet mode door actuator electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 6553 7. Remove the remaining upper evaporator core covers screws and the evaporator core cover. 8. Remove the evaporator core. 9. To install, reverse the removal procedure. - Lubricate the refrigerant system with the correct amount of clean PAG oil. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) SENSOR A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance The ACET sensor measures the evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance changes the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improve defrost/demist performance, and reduce A/C clutch cycling. NOTE: These values can vary 15% due to sensor and VREF variations. Voltage values were calculated for VREF equals 5.0 volts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Evaporator Core Orifice Tube Expansion Block/Orifice Tube: Description and Operation Evaporator Core Orifice Tube EVAPORATOR CORE ORIFICE TUBE NOTE: A new evaporator core orifice tube should be installed whenever a new A/C compressor is installed. The A/C evaporator core orifice has the following characteristics: - It is located in the condenser-to-evaporator line at the condenser fitting - It has filter screens located on the inlet and outlet ends of the tube body - The inlet filter screen acts as a strainer for the liquid refrigerant flowing through the evaporator core orifice tube - O-ring seals on the evaporator core orifice tube prevent the high-pressure liquid refrigerant from bypassing the evaporator core orifice tube - Adjustment or service cannot be carried out to the evaporator core orifice tube. A new evaporator core orifice must be installed Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Evaporator Core Orifice Tube > Page 6561 Expansion Block/Orifice Tube: Description and Operation A/C Pressure Transducer A/C PRESSURE TRANSDUCER The A/C pressure transducer communicates the compressor discharge pressure to the PCM. The PCM will interrupt A/C compressor operation in the event that the A/C pressure transducer indicates excessively high system discharge pressures. It is also used to sense low charge conditions. If the pressure is below a predetermined value for a given ambient temperature, the PCM will not allow the clutch to engage. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Page 6562 Expansion Block/Orifice Tube: Service and Repair EVAPORATOR CORE ORIFICE Special Tool(s) Special Tool(s) Removal 1. Recover the refrigerant. 2. Disconnect the evaporator core orifice access fitting. - Discard the O-ring seal. 3. Inspect the evaporator core orifice for damage before attempting to remove it from the line. 4. If the evaporator core orifice is intact, engage the special tool. Hold the T-handle stationary while rotating the tool body to remove the evaporator core orifice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Page 6563 5. If the evaporator core orifice is broken, screw the end of the special tool into the broken orifice. Hold the T-handle stationary while rotating the tool body to remove the evaporator core orifice. Installation 1. Lubricate the evaporator core orifice O-rings in clean PAG oil and install the evaporator core orifice using the special tool. 2. Connect the evaporator core orifice access fitting. - Install a new O-ring seal. 3. Lubricate the refrigerant system with the correct amount of clean PAG oil. 4. Evacuate, leak test and charge the refrigerant system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection Heater Core: Testing and Inspection HEATER CORE 1. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores were good and did not require replacement. If a heater core leak is suspected, the heater core must be tested by carrying out the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly as follows: Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. 2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Check the integrity of the heater water hose clamps. Heater Core - Plugged 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core inlet and outlet hose to see if they are hot. If the inlet hose is not hot: the thermostat is not working correctly. If the outlet hose is not hot: the heater core may have an air pocket. - the heater core may be restricted or plugged. Heater Core - Pressure Test Use the Radiator/Heater Core Pressure Tester to carry out the pressure test. 1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. Clamp off the heater hoses. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 in) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and Adapter BT-7422-A from the Radiator/Heater Core Pressure Tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Radiator/Heater Core Pressure Tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of 3 minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the bench test. Heater Core - Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 in) test heater water hoses with plug and adapter to the core tubes. Then connect the Radiator/Heater Core Pressure Tester to the adapter. 4. Apply 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new heater core. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection > Page 6567 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection > Page 6568 Heater Core: Service and Repair HEATER CORE Removal and Installation NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 1. Remove the heater core and evaporator core housing. 2. Remove the dash panel seal from the heater core tubes. 3. Position the temperature blend door actuator aside in the following sequence. 1 Remove the 3 temperature blend door actuator screws. 2 Position the temperature blend door actuator aside. 4. Remove the heater core cover in the following sequence. 1 Remove the 4 heater core cover screws. 2 Remove the heater core cover. 5. Remove the heater core. 6. NOTE: The heater core seal must be correctly installed to prevent airflow from bypassing the heater core. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures Heater Hose: Customer Interest A/C - Compressor Shuts OFF in High Temperatures TSB 07-24-7 12/10/07 A/C COMPRESSOR SHUTOFF - HIGH AMBIENT TEMPERATURES - VEHICLE STATIONARY IN GEAR FORD: 2007-2008 F-150, F-150 LINCOLN: 2007-2008 Mark LT ISSUE Some 2007-2008 Mark LT and F-150 vehicles equipped with 5.4L or 4.6L engine only, may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C), when the vehicle is stationary for periods longer than 15 minutes, with the transmission in gear. Idling in gear and extreme ambient temperatures may cause the vehicle control systems to disable A/C compressor operation. ACTION Follow the Service Procedure steps to replace the A/C compressor pulley and coolant pump pulley. SERVICE PROCEDURE NOTE THIS TSB IS INTENDED TO RESTORE A/C COMPRESSOR OPERATION IN EXTREME HIGH AMBIENT TEMPERATURES WHEN THE TRANSMISSION IS PLACED IN THE PARK POSITION. DO NOT ATTEMPT TO ADDRESS CUSTOMER CONCERNS OF GENERAL A/C TEMPERATURE OUTPUT PERFORMANCE WITH THIS TSB. THIS TSB WILL NOT IMPROVE A/C SYSTEM DUCT TEMPERATURE OUTPUT PERFORMANCE. NOTE DURING EXTREME HIGH AMBIENT TEMPERATURES WHEN IDLING STATIONARY FOR EXTENDED PERIODS OF TIME IN GEAR, IT IS RECOMMENDED TO OPERATE THE A/C IN THE MAX POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, AND PUT THE TRANSMISSION INTO THE PARK POSITION TO CONTINUE TO RECEIVE COOL AIR FROM THE A/C SYSTEM. 1. Replace the A/C compressor pulley. Follow Workshop Manual (WSM), Section 412-01 for removal and installation details. 2. Replace the coolant pump pulley. Follow WSM, Section 303-03 for removal and installation details. 3. Drain approximately 1 quart of coolant from the cooling system into a clean container which will permit reuse of coolant in the vehicle. Refer to WSM, Section 303-03. 4. Replace the clamp on the heater core feed hose, near the right hand front of engine, at the water pump outlet pipe connection point. 5. Refill the cooling system. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072407A 2007-2008 F-150 4X2, 1.7 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X2. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures > Page 6577 8509A,8620F, 8616A, 18472A). 072407B 2007-2008 F-150 4X4, 1.9 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X4. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, 8509A,8620F, 8616A, 18472A). DEALER CODING CONDITION BASIC PART NO. CODE 8A616 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures Heater Hose: All Technical Service Bulletins A/C - Compressor Shuts OFF in High Temperatures TSB 07-24-7 12/10/07 A/C COMPRESSOR SHUTOFF - HIGH AMBIENT TEMPERATURES - VEHICLE STATIONARY IN GEAR FORD: 2007-2008 F-150, F-150 LINCOLN: 2007-2008 Mark LT ISSUE Some 2007-2008 Mark LT and F-150 vehicles equipped with 5.4L or 4.6L engine only, may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C), when the vehicle is stationary for periods longer than 15 minutes, with the transmission in gear. Idling in gear and extreme ambient temperatures may cause the vehicle control systems to disable A/C compressor operation. ACTION Follow the Service Procedure steps to replace the A/C compressor pulley and coolant pump pulley. SERVICE PROCEDURE NOTE THIS TSB IS INTENDED TO RESTORE A/C COMPRESSOR OPERATION IN EXTREME HIGH AMBIENT TEMPERATURES WHEN THE TRANSMISSION IS PLACED IN THE PARK POSITION. DO NOT ATTEMPT TO ADDRESS CUSTOMER CONCERNS OF GENERAL A/C TEMPERATURE OUTPUT PERFORMANCE WITH THIS TSB. THIS TSB WILL NOT IMPROVE A/C SYSTEM DUCT TEMPERATURE OUTPUT PERFORMANCE. NOTE DURING EXTREME HIGH AMBIENT TEMPERATURES WHEN IDLING STATIONARY FOR EXTENDED PERIODS OF TIME IN GEAR, IT IS RECOMMENDED TO OPERATE THE A/C IN THE MAX POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, AND PUT THE TRANSMISSION INTO THE PARK POSITION TO CONTINUE TO RECEIVE COOL AIR FROM THE A/C SYSTEM. 1. Replace the A/C compressor pulley. Follow Workshop Manual (WSM), Section 412-01 for removal and installation details. 2. Replace the coolant pump pulley. Follow WSM, Section 303-03 for removal and installation details. 3. Drain approximately 1 quart of coolant from the cooling system into a clean container which will permit reuse of coolant in the vehicle. Refer to WSM, Section 303-03. 4. Replace the clamp on the heater core feed hose, near the right hand front of engine, at the water pump outlet pipe connection point. 5. Refill the cooling system. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072407A 2007-2008 F-150 4X2, 1.7 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X2. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures > Page 6583 8509A,8620F, 8616A, 18472A). 072407B 2007-2008 F-150 4X4, 1.9 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X4. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, 8509A,8620F, 8616A, 18472A). DEALER CODING CONDITION BASIC PART NO. CODE 8A616 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation High Pressure Safety Valve HVAC: Description and Operation A/C PRESSURE RELIEF VALVE NOTE: If the A/C compressor is operating within limits and the A/C pressure relief valve is venting, or if the A/C pressure relief valve is leaking around the threads, replace the A/C pressure relief valve and O-ring seal. If the A/C pressure relief valve still vents after it is replaced, diagnose the refrigerant system for a restriction. An A/C pressure relief valve is incorporated in the A/C compressor to prevent damage to the A/C compressor and other system components by relieving unusually high system discharge pressure buildups. The A/C pressure relief valve is a separate component and can be replaced separately from the A/C compressor. It is necessary to recover the refrigerant before removing the A/C pressure relief valve. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line Hose/Line HVAC: Service and Repair Compressor To Condenser Discharge Line COMPRESSOR TO CONDENSER DISCHARGE LINE Removal and Installation 1. Recover the refrigerant. 2. Detach the wire harness from the compressor-to-condenser discharge line. 3. Remove the A/C compressor discharge fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 6591 4. Disconnect the A/C pressure transducer electrical connector. 5. Disconnect the condenser inlet fitting. - Discard the O-ring seal. - To install, tighten to 25 Nm (18 lb-ft). 6. Remove the compressor-to-condenser discharge line. 7. To install, reverse the removal procedure. - Install a new gasket seal and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 8. Evacuate, leak test and charge the refrigerant system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 6592 Hose/Line HVAC: Service and Repair Condenser To Evaporator Line CONDENSER TO EVAPORATOR LINE Removal and Installation 1. Disconnect the battery. 2. Recover the refrigerant. 3. Remove the PCM. 4. Disconnect the A/C cycling switch electrical connector. 5. Remove the PCM bracket in the following sequence. 1 Remove the 3 PCM bracket bolts. 2 Remove the PCM bracket. - To install, tighten to 10 Nm (89 lb-in). 6. Disconnect the evaporator inlet fitting. - Discard the O-ring seals. 7. Disconnect the condenser outlet fitting. - Discard the O-ring seal. - To install, tighten to 25 Nm (18 lb-ft). 8. Remove the condenser to evaporator line. 9. To install, reverse the removal procedure. - Install new O-ring seals. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 6593 - Lubricate the refrigerant system with the correct amount of clean PAG oil. 10. Evacuate, leak test and charge the refrigerant system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 6594 Hose/Line HVAC: Service and Repair Suction Accumulator To Compressor Line SUCTION ACCUMULATOR TO COMPRESSOR LINE Removal and Installation 1. Recover the refrigerant. 2. Remove the A/C compressor suction fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). 3. Remove the suction accumulator outlet fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 8 Nm (71 lb-in). 4. Remove the suction accumulator-to-compressor line. 5. To install, reverse the removal procedure. - Install a new gasket seal and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 6. Evacuate, leak test and charge the refrigerant system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing Housing Assembly HVAC: Service and Repair Heater Core and Evaporator Core Housing HEATER CORE AND EVAPORATOR CORE HOUSING Part 1 Part 2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 6599 Removal and Installation NOTE: - If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. - If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. - Failure to correctly install the evaporator core seal when installing the evaporator core will result in decreased A/C cooling efficiency due to airflow bypassing the evaporator core. 1. Remove the instrument panel. 2. Remove the suction accumulator. 3. Disconnect the evaporator core spring lock coupling. - Discard the O-ring seals. 4. Clamp off and disconnect the 2 heater core quick disconnect fittings. 5. Remove the 3 heater core and evaporator core housing nuts. - To install, tighten to 9 Nm (80 lb-in). 6. Disconnect the 2 harness electrical connectors. 7. Remove the air inlet duct bracket nut. - To install, tighten to 7 Nm (62 lb-in). 8. Remove the bolt and position the junction box aside. 9. NOTE: For vehicles equipped with a rear footwell duct, the heater core and evaporator core housing must be carefully detached from the dash panel and then tilted toward the rear of the vehicle to detach it from the rear footwell duct connection. Loosen the nut and remove the heater core and evaporator core housing. 1 Detach the clip. 2 Completely loosen the plenum chamber nut. To install, tighten to 7 Nm (62 lb-in). 3 Remove the heater core and evaporator core housing. 10. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 11. Fill the engine cooling system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 6600 Housing Assembly HVAC: Service and Repair Plenum Chamber PLENUM CHAMBER Removal and Installation 1. Remove the heater core and evaporator core housing. 2. Disconnect the 2 mode door actuator electrical connectors, detach the routing clip and position the wire harness aside. 3. Remove the 3 upper plenum chamber screws. 4. Remove the 5 lower plenum chamber screws and the plenum. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R-1134a Refrigerant YN-19 (US): CYN-16-P or CYN-16-R (Canada)...........................WSH-M17B19-A (Specification) - 0.96 kg (34 oz) (Fill Capacity) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 6605 Refrigerant: Fluid Type Specifications R-1134a Refrigerant YN-19 (US): CYN-16-P or CYN-16-R (Canada)...........................WSH-M17B19-A (Specification) - 0.96 kg (34 oz) (Fill Capacity) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant compressor Oil (R-134a Systems) YN-12-D................................................WSH-M1C231-B (Specification) - 237 ml (8 fl oz.) (Fill Capacity) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 6610 Refrigerant Oil: Fluid Type Specifications Refrigerant compressor Oil (R-134a Systems) YN-12-D................................................WSH-M1C231-B (Specification) - 237 ml (8 fl oz.) (Fill Capacity) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations View 151-2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Cycling Switch C130 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Cycling Switch > Page 6616 C1260 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch A/C CYCLING SWITCH The A/C cycling switch is mounted on a Schrader valve-type fitting on the suction accumulator. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction pressure to control the operation of the A/C cycling switch. - Battery voltage is present at one side of the A/C cycling switch at all times when the ignition switch is in the RUN position. - When the switch contacts are closed, the battery voltage circuit is completed to the PCM to signal that the low-side refrigerant system pressure is acceptable for A/C compressor operation. - When the switch contacts are open, the battery voltage circuit is opened to signal the PCM that the low-side refrigerant system pressure is too low for A/C compressor operation. - The A/C cycling switch will control the evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the evaporator core and blockage of airflow. - It is not necessary to recover the refrigerant to remove the A/C cycling switch. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 6619 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) Cycling Switch Air Conditioning (A/C) Cycling Switch The A/C cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C cycling switch opens, the PCM turns off the A/C clutch. For information on the specific function of the A/C cycling switch, refer to Heating and Air Conditioning, Climate Control System Air Conditioning System Overview. Also, refer to the applicable Vehicle/Diagrams for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. Some applications do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the communication link. Air Conditioning (A/C) High Pressure Switch The A/C high pressure switch is used for additional A/C system pressure control. The A/C high pressure switch is either dual function for multiple speed, relay controlled electric fan applications, or single function for all others. For refrigerant containment control, the normally closed high pressure contacts open at a predetermined A/C pressure. This results in the A/C turning off, preventing the A/C pressure from rising to a level that would open the A/C high pressure relief valve. For fan control, the normally open medium pressure contacts close at a predetermined A/C pressure. This grounds the ACPSW circuit input to the PCM. The PCM then turns on the high speed fan to help reduce the pressure. For additional information, refer to Heating and Air Conditioning, Climate Control System, Air Conditioning System Overview or Vehicle/Diagrams. Air Conditioning Pressure (ACP) Transducer Sensor A/C Pressure Transducer Sensor Output Voltage Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 6620 Typical ACP Transducer Sensor The ACP transducer sensor is located in the high pressure (discharge) side of the A/C system. The ACP transducer sensor provides a voltage signal to the PCM that is proportional to the A/C pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 6625 Blower Motor Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 6626 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6630 Compressor Clutch Relay: Description and Operation AIR CONDITIONING (A/C) CLUTCH RELAY (A/CCR) NOTE: The PCM PIDs WAC and wide open throttle air conditioning cutoff fault (WACF) are used to monitor the A/CCR output. The A/CCR is wired normally open. There is no direct electrical connection between the A/C switch or electronic automatic temperature control (EATC) module and the A/C clutch. The PCM receives a signal indicating that A/C is requested. For some applications, this message is sent through the communications network. When A/C is requested, the PCM checks other A/C related inputs that are available, such as A/C pressure switch and A/C cycling switch. If these inputs indicate A/C operation is OK, and the engine conditions are OK (coolant temperature, engine RPM, throttle position), the PCM grounds the A/CCR output, closing the relay contacts and sending voltage to the A/CCR. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > 4x4 Relay Box Compressor Clutch Relay: Testing and Inspection 4x4 Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > 4x4 Relay Box > Page 6633 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > 4x4 Relay Box > Page 6634 Compressor Clutch Relay: Testing and Inspection 4x2 Relay Box Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > 4x4 Relay Box > Page 6635 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > HVAC Module, EATC View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > HVAC Module, EATC > Page 6640 View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC Module, EATC Control Module HVAC: Diagrams HVAC Module, EATC C228A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC Module, EATC > Page 6643 C228B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC Module, EATC > Page 6644 Control Module HVAC: Diagrams HVAC Module, EMTC C294A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC Module, EATC > Page 6645 C294B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Locations View 151-20 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations View 151-2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6653 C132 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6654 In-Vehicle Temperature Sensor - HVAC Module - Electronic Automatic Temperature Control (EATC) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations View 151-18 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 6658 C271 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 6659 Blower Motor Switch: Description and Operation BLOWER MOTOR SWITCH The blower motor switch is mounted in the HVAC module and controls blower motor speed by adding or bypassing resistors in the blower motor resistor in all function selector switch positions except OFF. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 6660 Blower Motor Switch: Service and Repair BLOWER MOTOR SPEED CONTROL Removal and Installation 1. NOTE: The blower motor speed control can be accessed from below the RH side of the instrument panel. Disconnect the blower motor speed control electrical connector. 2. Remove the blower motor speed control screw. 3. Detach the blower motor speed control. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 6664 C233 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 6665 Cabin Temperature Sensor / Switch: Service and Repair IN-VEHICLE TEMPERATURE SENSOR Removal and Installation 1. Remove the instrument cluster finish panel. 2. Remove the 2 in-vehicle temperature sensor screws. 3. Remove the temperature sensor finish panel. 4. Remove the in-vehicle temperature sensor. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) SENSOR A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance The ACET sensor measures the evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance changes the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improve defrost/demist performance, and reduce A/C clutch cycling. NOTE: These values can vary 15% due to sensor and VREF variations. Voltage values were calculated for VREF equals 5.0 volts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations View 151-2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Cycling Switch C130 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Cycling Switch > Page 6674 C1260 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch A/C CYCLING SWITCH The A/C cycling switch is mounted on a Schrader valve-type fitting on the suction accumulator. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction pressure to control the operation of the A/C cycling switch. - Battery voltage is present at one side of the A/C cycling switch at all times when the ignition switch is in the RUN position. - When the switch contacts are closed, the battery voltage circuit is completed to the PCM to signal that the low-side refrigerant system pressure is acceptable for A/C compressor operation. - When the switch contacts are open, the battery voltage circuit is opened to signal the PCM that the low-side refrigerant system pressure is too low for A/C compressor operation. - The A/C cycling switch will control the evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the evaporator core and blockage of airflow. - It is not necessary to recover the refrigerant to remove the A/C cycling switch. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 6677 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) Cycling Switch Air Conditioning (A/C) Cycling Switch The A/C cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C cycling switch opens, the PCM turns off the A/C clutch. For information on the specific function of the A/C cycling switch, refer to Heating and Air Conditioning, Climate Control System Air Conditioning System Overview. Also, refer to the applicable Vehicle/Diagrams for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. Some applications do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the communication link. Air Conditioning (A/C) High Pressure Switch The A/C high pressure switch is used for additional A/C system pressure control. The A/C high pressure switch is either dual function for multiple speed, relay controlled electric fan applications, or single function for all others. For refrigerant containment control, the normally closed high pressure contacts open at a predetermined A/C pressure. This results in the A/C turning off, preventing the A/C pressure from rising to a level that would open the A/C high pressure relief valve. For fan control, the normally open medium pressure contacts close at a predetermined A/C pressure. This grounds the ACPSW circuit input to the PCM. The PCM then turns on the high speed fan to help reduce the pressure. For additional information, refer to Heating and Air Conditioning, Climate Control System, Air Conditioning System Overview or Vehicle/Diagrams. Air Conditioning Pressure (ACP) Transducer Sensor A/C Pressure Transducer Sensor Output Voltage Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 6678 Typical ACP Transducer Sensor The ACP transducer sensor is located in the high pressure (discharge) side of the A/C system. The ACP transducer sensor provides a voltage signal to the PCM that is proportional to the A/C pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 6682 C286 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation SERVICE GAUGE PORT VALVES The high-pressure service gauge port valve is located on the compressor-to-condenser discharge line. The low-pressure service gauge port valve is located on the suction accumulator-to-compressor line. The fitting is an integral part of the refrigeration line or component. - Special couplings are required for both the high-side and low-side service gauge ports. - A very small amount of leakage will always be detectable around the Schrader-type valve with the service gauge port valve cap removed and is considered normal. A new Schrader-type valve core can be installed if the seal leaks excessively. - The service gauge port valve caps are used as primary seals in the refrigerant system to prevent leakage through the Schrader-type valves from reaching the atmosphere. Always install and tighten the A/C service gauge port valve caps to the correct torque after they are removed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 6689 C286 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment Repairs and Inspections Required After a Collision: Service and Repair Inspection and Repair After A Supplemental Restraint System (SRS) Deployment Inspection and Repair After a Supplemental Restraint System (SRS) Deployment WARNING: Remove restraint system diagnostic tools from the vehicle prior to road testing. If tools are not removed, the supplemental restraint system (SRS) device may not deploy in a crash. Failure to follow this instruction may result in serious personal injury or death in a crash and possibly violate vehicle safety standards. NOTE: After diagnosing or repairing a supplemental restraint system (SRS), the restraint system diagnostic tools (if required) must be removed before operating the vehicle over the road. NOTE: Deployable devices (such as air bag modules, pretensioners) may deploy alone or in various combinations depending on the impact event. NOTE: Always refer to the appropriate workshop manual procedures prior to carrying out vehicle repairs affecting the SRS and safety belt system. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. NOTE: Refer to the correct removal and installation procedure for all SRS components being installed. When any deployable device or combination of devices are deployed and/or the restraints control module (RCM) has the DTC B1231 (Event Threshold Exceeded) in memory, the repair of the vehicle's SRS is to include the removal of all deployed devices and the installation of new deployable devices, the removal and installation of new impact sensors, and the removal and installation of a new RCM. DTCs must cleared from all required modules after repairs are carried out. Vehicles with occupant classification sensor (OCS) system 2. NOTE: After installation of new occupant classification sensor (OCS) system components carry out the OCS System Reset procedure as instructed in the workshop manual. Refer to the appropriate workshop manual for OCS system removal and installation procedure. When a vehicle has been involved in a collision and the occupant classification system module (OCSM) has DTC B1231 stored in memory, the repair of the OCS system is to include the following procedures for the specified system: - For rail type OCS system, inspect the passenger side floorpan for damage and repair as necessary. Install new OCS system rails. - For weight sensor bolt type OCS system, inspect the passenger side floorpan for damage and repair as necessary. Install a new seat track with OCS system weight sensor bolts. DTC must be cleared from the OCSM before carrying out Occupant Classification Sensor (OCS) System Reset. Do not install a new OCSM unless DTC B1231 cannot be cleared. - NOTE: Most bladder type OCSM do not store a DTC B1231 in memory after deployment. The DTC B1231 is stored only by the RCM. For bladder type OCS system, inspect for damage and repair as necessary. If installation of an OCS system component is required, an OCS system service kit must be installed. All vehicles 3. When any damage to the impact sensor mounting points or mounting hardware has occurred, repair or install new mounting points and mounting hardware as needed. 4. When the driver air bag module has deployed, a new clockspring must be installed. 5. New driver and/or front passenger safety belt systems (including retractors, buckles and height adjusters) must be installed if the vehicle is involved in a collision that results in deployment of the driver and/or front passenger safety belt pretensioners. For additional information, refer to Safety Belt System. 6. Inspect the entire vehicle for damage, including the following components: Steering column (deployable column if equipped) Instrument panel knee bolsters and mounting points Instrument panel braces and brackets Instrument panel and mounting points Seats and seat mounting points Safety belts, safety belt buckles and safety belt retractors. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment > Page 6695 SRS wiring, wiring harnesses and connectors 7. After carrying out the review and inspection of the entire vehicle for damage, repair or install new components as needed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment > Page 6696 Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After A Collision SAFETY BELT PROCEDURE AFTER A COLLISION WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Before installing a 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. 2. Install the new safety belt(s). Carry out the Functional Test. See: Seat Belt Systems/Testing and Inspection/Component Tests and General Diagnostics Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Adaptive Collapsible Steering Column > Component Information > Service and Repair Adaptive Collapsible Steering Column: Service and Repair DEPLOYABLE STEERING COLUMN - IN-VEHICLE DEPLOYMENT WARNING: Deploy all supplemental restraint system (SRS) devices (air bags, pretensioners, load limiters, etc.) outdoors with all personnel at least 9.14 meters (30 feet) away to make sure of personal safety. Due to the loud report which occurs when an SRS device is deployed, hearing protection is required. Failure to follow these instructions may result in serious personal injury. 1. Depower the SRS. 2. NOTE: It may be necessary to lower or remove the deployable steering column from the instrument panel to access the deployable steering column electrical connector. Access the deployable steering column electrical connector. 3. NOTE: If the deployable steering column does not have a hard-wired pigtail, it will be necessary to cut the wires and connector(s) from the vehicle wire harness and reconnect to the deployable steering column. Cut each of the deployable steering column wires, leaving at least 4 inches to work with. 4. Remove any sheathing (if present) and strip the insulation from the ends of the cut wires. 5. Make a jumper harness to deploy the deployable steering column. - Obtain 2 wires (20 gauge minimum) at least 9.14 m (30 ft) long and strip both ends of each wire. - At one end of the jumper harness, connect the wires together. 6. Using the end of the jumper harness that the wires are not connected together, attach each wire of the jumper harness to each wire of the deployable steering column. Use tape or other insulating material to make sure that the leads do not make contact with each other. 7. Remain at least 9.14 m (30 ft) away from the deployable steering column. 8. From the end of the jumper harness that is not connected to the deployable steering column, disconnect the 2 wires of the jumper harness from each other. 9. Deploy the deployable steering column by touching the ends of the 2 wires of the jumper harness to the terminals of a 12-volt battery. 10. To allow for cooling, wait at least 10 minutes before approaching the deployed steering column. 11. Dispose of the deployed steering column in the same manner as any other part to be scrapped. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) Depowering Procedure WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, remove the trim panel, the cover and the RCM fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install the RCM fuse 19 (10A) to the CJB and install the cover and trim panel. 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6705 4. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6706 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, remove the trim panel, the cover, and the RCM fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Remove the driver air bag module. 8. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6707 9. While pushing in on the 2 glove compartment door tabs, position the glove compartment downward. 10. Through the glove compartment opening, release the tabs and disconnect the LH passenger air bag module electrical connector. 11. Attach the restraint system diagnostic tool to the vehicle harness side of the LH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6708 12. Through the glove compartment opening, release the tabs and disconnect the RH passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the RH passenger air bag module electrical connector. 14. Install the RCM fuse 19 (10A) to the CJB. 15. Connect the battery ground cable. Reactivation 1. Remove the RCM fuse 19 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the RH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6709 4. Through the glove compartment opening, connect the RH passenger air bag module electrical connector. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the LH passenger air bag module electrical connector. 6. Through the glove compartment opening, connect the LH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6710 7. Close the glove compartment. 8. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 9. Turn the ignition switch from OFF to ON. 10. Install the RCM fuse 19 (10A) to the CJB and install the cover and trim panel. 11. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 12. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Passenger Air Bag Module #1 View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Passenger Air Bag Module #1 > Page 6715 View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Passenger Air Bag #1 C256A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Passenger Air Bag #1 > Page 6718 C256B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module Air Bag: Service and Repair Driver Air Bag Module DRIVER AIR BAG MODULE Removal WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - Do not repaint air bag modules with discolored or damaged trim covers or deployment doors; new air bag modules must be installed. Failure to follow this instruction may result in the air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Depower the SRS. 2. Remove the 2 driver air bag module bolt caps. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6721 3. Remove the 2 driver air bag module bolts - To install, tighten to 10 Nm (89 lb-in). 4. Partially remove the driver air bag module from the steering wheel. 5. Remove the driver air bag module from the steering wheel. 1 Disconnect the horn switch electrical connector. 2 Disconnect the black driver air bag module electrical connector. 3 Disconnect the gray driver air bag module electrical connector. 4 Remove the driver air bag module from the steering wheel. Installation 1. CAUTION: The driver air bag module electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Damage to the connector or component may occur. Install the driver air bag module. 1 Connect the horn switch electrical connector. 2 Connect the black driver air bag module electrical connector. 3 Connect the gray driver air bag module electrical connector. 4 CAUTION: Make sure the driver air bag module wiring lays over the steering wheel bolt and does not get trapped while positioning the driver air bag module to the steering wheel. Failure to follow these instructions may result in component damage and/or system failure. Position the driver air bag module to the steering wheel. 2. Install the 2 driver air bag module bolts. - Tighten to 10 Nm (89 lb-in). 3. Install the 2 driver air bag module bolt caps. 4. Repower the SRS. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6722 Air Bag: Service and Repair Passenger Air Bag Module PASSENGER AIR BAG MODULE Removal and Installation WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - Do not repaint air bag modules with discolored or damaged trim covers or deployment doors; new air bag modules must be installed. Failure to follow this instruction may result in the air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Depower the SRS. 2. While pushing in on the 2 glove compartment door tabs, position the glove compartment downward. 3. Remove the passenger air bag module bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 6723 4. Remove the RH defrost grille. 5. Remove the 2 pin-type retainers that retain the passenger air bag module deployment door to the instrument panel (if equipped). 6. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment doors. Damage to the air bag module may occur. Reaching one hand into the glove compartment opening, push out on the front of the passenger air bag module, releasing the clips at the front of the bag and partially remove the passenger air bag module from the instrument panel. 7. Disconnect the 2 passenger air bag module electrical connector and remove the passenger air bag module. Installation 1. Connect the 2 passenger air bag module electrical connectors. 2. NOTE: Make sure the J-clips are in place before positioning the passenger air bag module to the instrument panel. Position the passenger air bag module into the instrument panel. 1 Angle the rear of the passenger air bag module deployment door so the tabs engage to the instrument panel. 2 Position the passenger air bag module into place and push down on the deployment door, engaging the remaining tabs. 3. Install the RH defrost grille. 4. Install the 2 pin-type retainers that retain the passenger air bag module deployment door to the instrument panel (if equipped). 5. Install the passenger air bag module bolts. - To install, tighten to 9 Nm (80 lb-in). 6. Close the glove compartment. 7. Repower the SRS. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6727 View 151-22 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6728 Air Bag Control Module: Diagrams C310A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6729 C310B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6730 Air Bag Control Module: Service and Repair RESTRAINTS CONTROL MODULE (RCM) Removal WARNING: - If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. - Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: - When installing a new restraints control module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. - The air bag warning indicator illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Depower the SRS. 2. If equipped, remove the floor console. 3. If equipped, remove the 20 percent front seat cushion. Pull up to release the retainers on the 20 percent front seat cushion and remove. 4. Disconnect the RCM large electrical connector. 1 Pinch the thumb tab and pivot the connector position assurance lever all the way back until it stops. 2 Pull out and disconnect the RCM electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6731 5. Disconnect the RCM small electrical connector. 6. Remove the RCM bolts. 7. Remove the RCM. Installation 1. Position the RCM and install the bolts. - Tighten to 12 Nm (9 lb-ft). 2. Make sure the connector position assurance lever is in the full RELEASE position before attempting to connect the connector. 3. CAUTION: Putting the large restraints control module (RCM) electrical connector into the RCM on an angle can cause bad electrical connections and damage components. NOTE: The RCM has been removed for clarity. Position the large RCM electrical connector into the RCM. - CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the restraints control module (RCM) before using the lever to fully seat the connector. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and a slight resistance is felt. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6732 4. Connect the large RCM electrical connector. - Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. 5. Connect the RCM small electrical connector. 6. If equipped, install the floor console. 7. If equipped, install the 20 percent front seat cushion. Align the retainers on the 20 percent seat cushion and press down firmly near the front of the cushion to seat the retainers. 8. Repower the SRS. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Diagrams C2286 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Diagrams > Page 6736 Air Bag Deactivation Indicator: Service and Repair PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR Passenger Air Bag Deactivation (PAD) Indicator Removal and Installation NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Depower the SRS. 2. Remove the instrument panel center finish panel. 3. Disconnect the passenger air bag deactivation (PAD) indicator electrical connector. 4. Remove the PAD indicator screws and PAD indicator. 5. To install, reverse the removal procedure. 6. Repower the SRS. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Clockspring Assembly / Spiral Cable: Diagrams C218A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6740 C218B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6741 Clockspring Assembly / Spiral Cable: Service and Repair CLOCKSPRING Removal NOTE: - The supplemental restraint system (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6742 1. Depower the SRS. 2. Make sure the road wheels are in the straight-ahead position. 3. Remove the driver air bag module. 4. Remove the steering wheel. 5. Remove the screw and lower steering column shroud. 6. Remove the 2 upper steering column shroud screws and upper steering column shroud. 7. If installing the same clockspring, apply 2 strips of masking tape across the clockspring to prevent accidental rotation when the clockspring is removed. 8. Remove the multi-function switch screw. 9. Remove the screw and the multi-function switch. - While releasing the retaining tab at the top of the multi-function switch, slide the multi-function switch up and aside. 10. Disconnect the clockspring electrical connectors. 11. Release the 3 clips and remove the clockspring. 12. Inspect the clockspring mounting bracket for damage and install a new mounting bracket as necessary. - To install, tighten to 6 Nm (53 lb-in). Installation 1. WARNING: If the clockspring is not correctly centralized, it may fail prematurely. If in doubt, repeat the centralizing procedure. Failure to follow these instructions may increase the risk of serious personal injury or death in a crash. CAUTION: Make sure the road wheels are in the straight-ahead position or damage to the clockspring can occur. If the vehicle's clockspring has rotated out of center, follow these steps to center the clockspring. 1 Hold the clockspring outer housing stationary. 2 CAUTION: Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and can be broken from its internal connection. While turning the rotor counterclockwise, carefully feel for the ribbon wire to run out of length and for a slight resistance. Stop turning at this point. 3 Turn the clockspring clockwise approximately 3 turns. This is the center point of the clockspring. Do not allow the rotor to turn from this position. To prevent accidental rotation until the clockspring is installed, 2 pieces of tape may be applied to the clockspring. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6743 2. NOTE: Slight turning of the clockspring rotor is allowable for alignment purposes to the steering column. With the flats of the clockspring aligned to the flats of the steering column, slide the clockspring onto the steering column. For vehicles receiving a new clockspring, remove the retaining pin. - For vehicles reusing the clockspring that was removed, remove the tape. 3. Connect the clockspring electrical connectors. - Make sure to align and completely seat the electrical connectors. 4. Install the multi-function switch and screw. 5. Install the upper steering column shroud and shroud screw. 6. Install the lower steering column shroud and screw. 7. Install the steering wheel. 8. Install the driver air bag module. 9. Repower the SRS. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations View 151-2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6747 C177 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6748 Impact Sensor: Testing and Inspection IMPACT SENSORS WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. For this vehicle line, the SRS uses one satellite sensor in addition to the RCM. The RCM is mounted to the center tunnel beneath the 20 percent seat or floor console (if equipped). All vehicles have one front impact severity sensor located in the front-center area of the vehicle, behind the grille mounted on the lower radiator support. Mounting orientation is critical for correct operation of all impact sensors. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6749 Impact Sensor: Service and Repair FRONT IMPACT SEVERITY SENSOR Removal and Installation WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: - The supplemental restraint system (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Depower the SRS. 2. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. CAUTION: If the hood latch support bracket is damaged in any way that would affect the way the front impact severity sensor mounts to its original manufactured position, a new hood latch support bracket must be installed. NOTE: The front impact severity sensor is mounted to the hood latch support bracket. Remove the front impact severity sensor bolt. To install, tighten to 12 Nm (9 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6750 3. NOTE: Make sure the hood latch support bracket and front impact severity sensor mating surfaces are clean and free of foreign material. Remove the front impact severity sensor and disconnect the electrical connector. When installing the front impact severity sensor, align the locators on the front impact severity sensor to the holes of the hood latch bracket. 4. To install, reverse the removal procedure. 5. Repower the SRS. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations View 151-29 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 6754 C3043 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Locations View 151-29 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Locations > Page 6758 C3042 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Locations > Page 6759 Seat Occupant Sensor: Description and Operation OCCUPANT CLASSIFICATION SENSOR (OCS) WARNING: Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. NOTE: - Occupant classification sensor (OCS) system components (set wiring harness, seat cushion frame, seat cushion foam pad, bladder with pressure sensor and occupant classification system module [OCSM]) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, an OCS system service kit (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness and OCSM) must be installed as an assembly. - To identify between a production OCS system and an OCS system service kit, inspect the OCSM electrical connector. A production OCS system allows the disconnection of the OCSM electrical connector. An OCS system service kit has the electrical connector glued to the OCSM, it cannot and should not be disconnected or altered. The OCS system is standard equipment on all front outboard passenger seats. For information on diagnosing or servicing the OCS system, refer to Air Bag Systems. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Locations > Page 6760 Seat Occupant Sensor: Service and Repair OCCUPANT CLASSIFICATION SENSOR Special Tool(s) Special Tool(s) Removal WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Locations > Page 6761 CAUTION: - While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - To prevent system failure, it is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. - Do not install a new heater mat on a front passenger seat cushion. If a new cushion heater mat is needed on the front passenger seat, an occupant classification sensor (OCS) service kit equipped with a heater mat must be installed. Failure to follow this instruction may result in incorrect operation of the OCS system. NOTE: - Occupant classification sensor (OCS) system components (seat wiring harness, seat cushion frame, seat cushion foam pad, bladder with pressure sensor and occupant classification system module [OCSM]) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, an OCS system service kit (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness and OCSM) must be installed as an assembly. - To identify between a production OCS system and an OCS service kit, inspect the OCSM electrical connector. A production OCS system allows the disconnect of the electrical connector from the OCSM. An OCS system service kit has the OCSM electrical connector glued to the module. It cannot and should not be disconnected or altered. - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Remove the passenger seat. 2. CAUTION: To prevent component damage and avoid setting DTCs, the following precautions must be taken when disconnecting the safety belt buckle pretensioner. The position assurance locking wedge must be in the released position when inserting or removing the electrical connector from the safety belt buckle and pretensioner. - Do not install the electrical connector by pushing on the position assurance locking wedge. - Make sure the electrical connector and position assurance locking wedge are fully seated after connecting to the safety belt buckle and pretensioner. Release the locking wedge on the safety belt buckle and pretensioner electrical connector. 3. Disconnect the safety belt buckle switch and pretensioner electrical connectors. 4. NOTE: Vehicles without seat integrated restraints (SIR) will have the belt tension sensor (BTS) connector at the B-pillar and will not have to be disconnected for this procedure. Disconnect the BTS electrical connector and route out the wire harness (vehicles with SIR only). 5. Remove the seat cushion nuts. 6. If equipped with manual lumbar, release the J-clip and route out the manual lumbar cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Locations > Page 6762 7. NOTE: Disconnect and release any remaining electrical connectors and pin-type retainers necessary to remove the seat cushion frame. Remove the seat cushion frame assembly. To aid in removal, recline the seat. - Remove the safety belt buckle from the seat cushion strap. 8. Release the seat cushion trim cover J-clips and pin-type retainers from the seat cushion frame. 9. At the front outboard side of the seat cushion frame, pull the trim cover back and release the 2 remaining clips. 10. Remove all the hog rings and separate the trim cover from the foam pad of the OCS assembly. Installation CAUTION: - While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - To prevent system failure, it is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. - Do not install a new heater mat on a front passenger seat cushion. If a new cushion heater mat is needed on the front passenger seat, an occupant classification sensor (OCS) service kit equipped with a heater mat must be installed. Failure to follow this instruction may result in incorrect operation of the OCS system. NOTE: OCS system components (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness and OCSM) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or cushion foam pad are needed, an OCS system service kit (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness and OCSM) must be installed as an assembly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Locations > Page 6763 1. Install the seat cushion trim cover. - Install hog rings to attach the seat cushion trim cover to the seat cushion foam pad of the OCS assembly at all locations from where they were removed. 2. At the front outboard side of the seat cushion frame, attach the 2 clips. 3. On vehicles equipped with SIR seats, attach the seat cushion trim cover J-clips to the seat cushion frame. - If equipped with manual lumbar, do not attach the rear inboard J-clip at this time. 4. Install the seat cushion assembly and the 4 nuts to the seat track. - Position the safety belt buckle through the seat cushion strap. - Tighten to 25 Nm (18 lb-ft). 5. If equipped, connect the backrest heated seat element electrical connector and attach any wire harness retainers to the seat cushion frame. 6. If equipped, connect the power seat track electrical connector and attach any wire harness retainers to the seat cushion frame. 7. NOTE: If equipped with manual lumbar, make sure this wire harness is routed above the manual lumbar cable. Connect the safety belt buckle pretensioner and safety belt buckle switch electrical connectors and attach the wire harness retainer to the seat track. 8. CAUTION: To prevent component damage and avoid setting DTCs, the following precautions must be taken: - The position assurance locking wedge must be in the released position when inserting the electrical connector in the safety belt buckle and pretensioner. - Do not install the electrical connector by pushing on the position assurance locking wedge. - Make sure the electrical connector and position assurance locking wedge are fully seated after connecting to the safety belt buckle and pretensioner. Fully engage the locking wedge on the safety belt buckle and pretensioner electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Locations > Page 6764 9. On vehicles with SIR seats, connect the BTS electrical connector. - Route the wire harness and connect the electrical connector. 10. If equipped, connect the manual lumbar cable. - Route the cable and attach the J-clip. 11. Install the passenger seat. Do not prove the SRS at this time. - Make sure the safety belts and buckles accessible to the occupants after installation. - Verify the safety belt retractor operates without excessive effort or binding. 12. WARNING: - Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. - Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. CAUTION: To prevent system failure, it is necessary to carry out the occupant classification sensor (OCS) system reset of the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed or an OCS system service kit is installed. A scan tool is used to trigger the command to carry out the OCS system reset. - To prevent system failure, the following precautions must be taken before carrying out the occupant classification sensor (OCS) system reset: Make sure the voltage to the occupant classification system module (OCSM) is above 8.0 volts and less than 18.0 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. NOTE: If the first attempt to carry out the OCS system reset is unsuccessful, a second attempt must be made. If the second attempt to carry out the OCS system reset is unsuccessful, a new OCS system service kit must be installed. Carry out the OCS system reset command using the scan tool. 13. Cycle the ignition switch from ON to OFF. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Locations > Page 6765 14. NOTE: The ignition switch must be cycled after the OCS system reset. Cycle the ignition switch from OFF to ON. 15. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. 16. NOTE: A prepaid return postcard is provided with a new OCS service kit. The serial number for the new part and the vehicle identification number (VIN) must be recorded and sent to Ford Motor Company. When installing a new OCS service kit, fill out the necessary information on the OCS service kit traceability card and return it along with the complete inoperative OCS system to Ford Motor Company. When returning the inoperative OCS system, include the following: seat cushion foam pad, seat cushion frame, bladder, OCSM, pressure sensor (transducer), hose, electrical connectors and wire harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations > Page 6769 C356 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Position Sensor - Manual Seat Track Seat Position Sensor: Service and Repair Seat Position Sensor - Manual Seat Track SEAT POSITION SENSOR - MANUAL SEAT TRACK Removal and Installation WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Depower the SRS. 2. Disconnect the seat position sensor electrical connector. 3. Remove the nut and seat position sensor. - To install, tighten to 8 Nm (71 lb-in). 4. To install, reverse the removal procedure. 5. Repower the SRS. - After installation and power is restored, position the driver seat from its forward most position to its rearmost position and then back again. While positioning the seat, make sure that the seat position sensor and bracket and the wire harness do not come in contact with any other part of the seat that may cause damage. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Position Sensor - Manual Seat Track > Page 6772 Seat Position Sensor: Service and Repair Seat Position Sensor - Power Seat Track SEAT POSITION SENSOR - POWER SEAT TRACK Removal and Installation WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. NOTE: The seat position sensor is mounted at the LH rear of the seat track. Position the driver seat rearward enough so that upon removal the sensor can clear the bracket. Position the driver seat to access the seat position sensor. 2. Depower the SRS. 3. Fold the seat backrest all the way forward. 4. Disconnect the seat position sensor electrical connector. 5. Remove the nuts and seat position sensor. - To install, tighten to 8 Nm (71 lb-in). 6. To install, reverse the removal procedure. 7. Repower the SRS. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Position Sensor - Manual Seat Track > Page 6773 - After installation and power is restored, position the driver seat from its forward most position to its rearmost position and then back again. While positioning the seat, make sure that the seat position sensor, bracket and wire harness do not come in contact with any other part of the seat that may cause damage. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Child Seat > Component Information > Description and Operation Child Seat: Description and Operation ATTACHING SAFETY SEATS WITH TETHER STRAPS Some manufacturers make child safety seats that include a tether strap that goes over the back of the vehicle seat and attaches to an anchoring point. Other manufacturers offer the tether strap as an accessory. Contact the manufacturer of the child safety seat for information about ordering a tether strap. Refer to Child Safety Seat Tether Anchor in the removal and installation portion or the Owner's Literature for usage information. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6781 View 151-22 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6782 Air Bag Control Module: Diagrams C310A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6783 C310B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6784 Air Bag Control Module: Service and Repair RESTRAINTS CONTROL MODULE (RCM) Removal WARNING: - If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. - Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: - When installing a new restraints control module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. - The air bag warning indicator illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Depower the SRS. 2. If equipped, remove the floor console. 3. If equipped, remove the 20 percent front seat cushion. Pull up to release the retainers on the 20 percent front seat cushion and remove. 4. Disconnect the RCM large electrical connector. 1 Pinch the thumb tab and pivot the connector position assurance lever all the way back until it stops. 2 Pull out and disconnect the RCM electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6785 5. Disconnect the RCM small electrical connector. 6. Remove the RCM bolts. 7. Remove the RCM. Installation 1. Position the RCM and install the bolts. - Tighten to 12 Nm (9 lb-ft). 2. Make sure the connector position assurance lever is in the full RELEASE position before attempting to connect the connector. 3. CAUTION: Putting the large restraints control module (RCM) electrical connector into the RCM on an angle can cause bad electrical connections and damage components. NOTE: The RCM has been removed for clarity. Position the large RCM electrical connector into the RCM. - CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the restraints control module (RCM) before using the lever to fully seat the connector. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and a slight resistance is felt. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6786 4. Connect the large RCM electrical connector. - Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. 5. Connect the RCM small electrical connector. 6. If equipped, install the floor console. 7. If equipped, install the 20 percent front seat cushion. Align the retainers on the 20 percent seat cushion and press down firmly near the front of the cushion to seat the retainers. 8. Repower the SRS. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations View 151-29 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 6790 C3043 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) Depowering Procedure WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, remove the trim panel, the cover and the RCM fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install the RCM fuse 19 (10A) to the CJB and install the cover and trim panel. 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6796 4. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6797 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, remove the trim panel, the cover, and the RCM fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Remove the driver air bag module. 8. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6798 9. While pushing in on the 2 glove compartment door tabs, position the glove compartment downward. 10. Through the glove compartment opening, release the tabs and disconnect the LH passenger air bag module electrical connector. 11. Attach the restraint system diagnostic tool to the vehicle harness side of the LH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6799 12. Through the glove compartment opening, release the tabs and disconnect the RH passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the RH passenger air bag module electrical connector. 14. Install the RCM fuse 19 (10A) to the CJB. 15. Connect the battery ground cable. Reactivation 1. Remove the RCM fuse 19 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the RH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6800 4. Through the glove compartment opening, connect the RH passenger air bag module electrical connector. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the LH passenger air bag module electrical connector. 6. Through the glove compartment opening, connect the LH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 6801 7. Close the glove compartment. 8. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 9. Turn the ignition switch from OFF to ON. 10. Install the RCM fuse 19 (10A) to the CJB and install the cover and trim panel. 11. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 12. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) 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 Child Safety Seat Tether Anchors WARNING: Always tighten the child safety seat tether anchor/bolt to specification. Failure to follow this instruction may result in the child's safety seat being incorrectly secured, which increases the risk of serious personal injury or death to the child in a sudden stop or crash. The second row child safety seat tether anchors are located directly behind the seat, attached to the back of the cab. If the child safety seat tether anchors were in use during a collision, inspect and install new anchors as necessary. Return the vehicle structure to its original production configuration. LATCH The LATCH system is a standardized and uniform attachment system for installing child safety seats in passenger vehicles. LATCH-equipped child safety seats have 2 lower attachments that connect to the vehicle portion of the LATCH system. The vehicle portion of the system consists of 2 attachment points (6 mm wires) attached to the rear seat risers and floor pan (SuperCab and SuperCrew). The attachment points protrude from the bight line between the seat cushion and seat backrest. If a child safety seat was in use during a collision, inspect the vehicle portion of the system for damage. If any of the attachment points (6 mm wires) are damaged, install a new LATCH assembly. Refer to the appropriate procedure in the Removal and Installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Safety Seat Tether Anchor Child Seat Tether Attachment: Service and Repair Child Safety Seat Tether Anchor CHILD SAFETY SEAT TETHER ANCHOR Child Safety Seat Tether Anchor Removal and Installation WARNING: - After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Safety Seat Tether Anchor > Page 6808 safety belt systems increases the risk of serious personal injury or death in a crash. - Always tighten the child safety seat tether anchor/bolt to specification. Failure to follow this instruction may result in the child's safety seat being incorrectly secured, which increases the risk of serious personal injury or death to the child in a sudden stop or crash. 1. To access the tether anchors, remove the rear seat backrest. 2. Remove the back of cab panel insulator. - Remove the pushpins and release the retaining clips. - Remove the back of cab panel insulator. 3. Remove the tether anchor bolt(s) and tether anchor(s). - To install, tighten to 30 Nm (22 lb-ft). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Safety Seat Tether Anchor > Page 6809 Child Seat Tether Attachment: Service and Repair Child Safety Seat Tether Anchor - LATCH, SuperCab and SuperCrew CHILD SAFETY SEAT TETHER ANCHOR - LATCH, SUPERCAB AND SUPERCREW Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Remove the rear seat backrest and seat cushion. 2. Remove the 3 LATCH-to-seat riser bolts and LATCH. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Safety Seat Tether Anchor > Page 6810 - To install, tighten to 48 Nm (35 lb-ft). 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair Seat Belt: Service and Repair SAFETY BELT - FRONT, CENTER Exploded View Safety Belt - Front, With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Page 6814 Safety Belt Buckle - Front, 20 Percent (Regular cab) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Page 6815 Safety Belt - Front, 20 Percent (SuperCab and SuperCrew) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Page 6816 Safety Belt - Front, Without Seat Integrated Restraints (SIR) (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Page 6817 Safety Belt - Front, Without Seat Integrated Restraints (SIR) (Part 2) Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. NOTE: This procedure is for the SuperCrew and Crew Cab 20 percent seat with a lap belt. 1. Remove the front 20 percent seat. 2. Remove the RH upper seat side trim panel screw and trim panel. 3. Remove the RH lower seat side trim panel screw and trim panel. 4. Remove the safety belt anchor bolt and safety belt. - To install, tighten to 55 Nm (41 lb-ft). - The anti-rotation tab must be correctly aligned for correct installation. 5. To install, reverse the removal procedure. 6. Check the active restraint system for correct operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Description and Operation > Safety Belt Buckle and Pretensioner Seat Belt Buckle: Description and Operation Safety Belt Buckle and Pretensioner SAFETY BELT BUCKLE AND PRETENSIONER The safety belt buckle and pretensioner is a pyrotechnic device that removes excess webbing from the safety belt when deployed. The pretensioner works in conjunction with the front air bag system. When the pretensioners deploy, this causes the buckle to move downward, removing excess webbing from the lap and shoulder safety belts. If the vehicle is involved in a collision that results in deployment of the safety belt pretensioners, a new driver and passenger seat belt system (including safety belt buckle and pretensioners, safety belt retractors and height adjusters) must be installed. For safety belt buckle pretensioner diagnostic information, refer to Air Bag Systems. For safety belt buckle pretensioner disposal information, refer to Air Bag Systems. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Description and Operation > Safety Belt Buckle and Pretensioner > Page 6822 Seat Belt Buckle: Description and Operation Safety Belt Buckle and Pretensioners SAFETY BELT BUCKLE AND PRETENSIONERS As part of the supplemental restraint system (SRS), the driver and passenger front seat safety belt buckles are equipped with pretensioners. The safety belt buckle and pretensioners are attached to the seat tracks. The safety belt buckle and pretensioners remove excess slack from the safety belt webbing and are activated by the restraints control module (RCM) when the module detects a collision event force exceeding a programmed limit. For information or if a deployment has occurred, refer to the appropriate procedure in Air Bag Systems. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Description and Operation > Page 6823 Seat Belt Buckle: Testing and Inspection FUNCTIONAL TEST - BUCKLE AND TONGUE The safety belt buckle and tongue assembly must operate freely during the latching and unlatching function. Fasten the safety belt by inserting the tongue (male portion) into the buckle (female portion). 1. Verify the following during the latching sequence: - Tongue insertion is not hindered by excessive effort - A "click" is heard when the buckle latches the tongue 2. Verify the system integrity by forcefully pulling on the belt webbing. 3. Unlatch the belt by fully depressing the buckle release button, and allowing the belt to release and retract. 4. Verify the following during the unlatching process: - Push-button depression does not require excessive effort - Tongue can be removed easily from the buckle - Repeat the above steps 3 times 5. If the inspection reveals an obvious concern(s) that can be readily identified, service as required. Do not attempt to carry out any repair on the buckle and tongue assembly. If a concern exists with either component, a new safety belt buckle and safety belt retractor assembly must be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner Seat Belt Buckle: Service and Repair Safety Belt Buckle and Pretensioner SAFETY BELT BUCKLE AND PRETENSIONER Exploded View Safety Belt - Front, With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 6826 Safety Belt Buckle - Front, 20 Percent (Regular cab) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 6827 Safety Belt - Front, 20 Percent (SuperCab and SuperCrew) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 6828 Safety Belt - Front, Without Seat Integrated Restraints (SIR) (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 6829 Safety Belt - Front, Without Seat Integrated Restraints (SIR) (Part 2) Removal and Installation WARNING: - After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. - Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the affected seat. 2. CAUTION: To prevent component damage and avoid setting diagnostic trouble codes (DTCs), the following precautions must be taken: - The position assurance locking wedge must be in the released position when inserting or removing the electrical connector from the safety belt buckle and pretensioner. - Do not install the electrical connector by pushing on the position assurance locking wedge. - Make sure the electrical connector and position assurance locking wedge are fully seated after connecting to the safety belt buckle and pretensioner. Release the locking wedge on the safety belt buckle and pretensioner electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 6830 3. Disconnect the safety belt buckle and pretensioner electrical connectors. 4. Remove the nut and safety belt buckle and pretensioner. - To install, tighten to 55 Nm (41 lb-ft). - The anti-rotation tab must be correctly aligned for correct installation. - When installing, pull the safety belt buckle through the anti-rattle retainer located on the side of the seat. 5. To install, reverse the removal procedure. 6. Check the active restraint system for correct operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 6831 Seat Belt Buckle: Service and Repair Safety Belt Buckle - Front, Center SAFETY BELT BUCKLE - FRONT, CENTER Exploded View Safety Belt - Front, With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 6832 Safety Belt Buckle - Front, 20 Percent (Regular cab) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 6833 Safety Belt - Front, 20 Percent (SuperCab and SuperCrew) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 6834 Safety Belt - Front, Without Seat Integrated Restraints (SIR) (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 6835 Safety Belt - Front, Without Seat Integrated Restraints (SIR) (Part 2) Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. All vehicles 1. Remove the front 20 percent seat. Regular cab safety belt mini-buckle 2. Remove the LH seat side trim panel screw and trim panel. 3. Remove the bolt and safety belt mini-buckle. - To install, tighten to 55 Nm (41 lb-ft). - The anti-rotation tab must be correctly aligned for correct installation. SuperCab and SuperCrew safety belt buckle 4. Remove the LH seat side trim panel screw and trim panel. 5. Remove the safety belt buckle bolt and safety belt buckle. - To install, tighten to 55 Nm (41 lb-ft). - The anti-rotation tab must be correctly aligned for correct installation. Regular cab safety belt buckle 6. Remove the RH upper seat side trim panel screw and trim panel. 7. Remove the RH lower seat side trim panel screw and trim panel. 8. Remove the safety belt buckle bolt and safety belt buckle. - To install, tighten to 55 Nm (41 lb-ft). - The anti-rotation tab must be correctly aligned for correct installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 6836 All vehicles 9. To install, reverse the removal procedure. 10. Check the active restraint system for correct operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 6837 Seat Belt Buckle: Service and Repair Safety Belt Buckle - Rear SAFETY BELT BUCKLE - REAR Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 6838 be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Remove the rear seat backrest. 2. Remove the nut and rear center and RH safety belt buckle assembly. - To install, tighten to 80 Nm (59 lb-ft). 3. NOTE: The LH safety belt buckle is attached to the rear center safety belt retractor assembly. Remove the rear center safety belt retractor assembly. 4. NOTE: Make sure the safety belt webbing is not twisted prior to installation. To install, reverse the removal procedure. 5. Check the active restraint system for correct operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger View 151-29 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 6843 View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver C3065 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 6846 C3066 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Description and Operation Seat Belt Extension: Description and Operation SAFETY BELT EXTENSION ASSEMBLY In certain cases, the safety belt may be too short even when it is fully extended. About 20 cm (8 in) can be added to the belt length by using a safety belt extension. Safety belt extensions are available at no cost from any Ford or Lincoln-Mercury dealer parts department. Safety belt extensions are only available with black webbing. Use only extensions manufactured by the same supplier as the safety belt. Manufacturer identification is located at the end of the webbing on the label. Also, use the safety belt extension only if the safety belt is too short for you when fully extended. Do not use an extension to change the fit of the shoulder belt across the torso. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair Seat Belt Height Adjuster: Service and Repair SAFETY BELT SHOULDER HEIGHT ADJUSTER Exploded View Safety Belt - Front, With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Page 6853 Safety Belt Buckle - Front, 20 Percent (Regular cab) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Page 6854 Safety Belt - Front, 20 Percent (SuperCab and SuperCrew) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Page 6855 Safety Belt - Front, Without Seat Integrated Restraints (SIR) (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Page 6856 Safety Belt - Front, Without Seat Integrated Restraints (SIR) (Part 2) Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Remove the front and rear door scuff plate. 2. Open the D-ring cover. 3. Remove the D-ring nut. - To install, tighten to 40 Nm (30 lb-ft). 4. Remove the B-pillar trim panel. 5. Remove the safety belt shoulder height adjuster cover. 6. Remove the safety belt shoulder height adjuster bolts and the safety belt shoulder height adjuster. - To install, tighten to 40 Nm (30 lb-ft). 7. To install, reverse the removal procedure. 8. Check the active restraint system for correct operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Description and Operation > Belt-Minder(R) Seat Belt Reminder Buzzer: Description and Operation Belt-Minder(R) BELT-MINDER(R) The Belt-Minder(R) feature is a supplemental warning to the safety belt warning function. This feature provides an additional reminder to the driver that the driver and/or passenger safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning indicator in the instrument cluster. The passenger Belt-Minder(R) feature is activated only when the occupant classification sensor (OCS) system detects a passenger in the right front seat and the passenger weight exceeds a programmed limit. To activate or deactivate the Belt-Minder(R) feature, refer to Instrument Panel, Gauges and Warning Indicators. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Description and Operation > Belt-Minder(R) > Page 6861 Seat Belt Reminder Buzzer: Description and Operation Safety Belt Warning Indicator and Chime SAFETY BELT WARNING INDICATOR AND CHIME The warning indicator and chime are reminders to fasten the safety belt. The system operates as follows: - If the driver safety belt is not buckled in the first 6 seconds after the ignition switch is turned to the RUN or START position, the warning indicator will illuminate and the chime will toggle from ON to OFF for 6 seconds, for one minute. - If the driver safety belt is buckled while the warning indicator is on and the chime is sounding, both the warning indicator and chime will turn off. - If the safety belt is buckled before the ignition is turned to the ON position, neither the warning indicator nor the chime will turn on. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation > Belt-Minder(R) Seat Belt Reminder Lamp: Description and Operation Belt-Minder(R) BELT-MINDER(R) The Belt-Minder(R) feature is a supplemental warning to the safety belt warning function. This feature provides an additional reminder to the driver that the driver and/or passenger safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning indicator in the instrument cluster. The passenger Belt-Minder(R) feature is activated only when the occupant classification sensor (OCS) system detects a passenger in the right front seat and the passenger weight exceeds a programmed limit. To activate or deactivate the Belt-Minder(R) feature, refer to Instrument Panel, Gauges and Warning Indicators. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation > Belt-Minder(R) > Page 6866 Seat Belt Reminder Lamp: Description and Operation Safety Belt Warning Indicator and Chime SAFETY BELT WARNING INDICATOR AND CHIME The warning indicator and chime are reminders to fasten the safety belt. The system operates as follows: - If the driver safety belt is not buckled in the first 6 seconds after the ignition switch is turned to the RUN or START position, the warning indicator will illuminate and the chime will toggle from ON to OFF for 6 seconds, for one minute. - If the driver safety belt is buckled while the warning indicator is on and the chime is sounding, both the warning indicator and chime will turn off. - If the safety belt is buckled before the ignition is turned to the ON position, neither the warning indicator nor the chime will turn on. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation > Dual Locking Mode Retractors Seat Belt Retractor: Description and Operation Dual Locking Mode Retractors DUAL LOCKING MODE RETRACTORS NOTE: When installing a new dual locking mode retractor, the retractor should be checked to make sure it is not in the automatic locking retractor (ALR) mode after installation in the stowed position. All continuous-loop, 3-point retractor systems (except the driver position) are equipped with the dual locking mode system. The emergency locking retractor (ELR) mode will allow the occupant freedom of movement, locking tight only on hard braking, hard cornering or an impact of approximately 8 km/h (5 mph). The ELR mode helps to reduce the forward movement of the driver and passengers. The ELR mode is continuously in operation at all seating positions. The ALR portion of this system does not allow the occupant freedom of movement. The ALR mode is used when locking a child seat in a seating position or when a tight belt fit is desired. The ALR mode is disengaged when the webbing is free to move in or out of the retractor. The ALR mode is automatically engaged when the webbing is fully extracted from the retractor and then allowed to retract. As the webbing is retracted back onto the spool an audible clicking sound is made indicating that the retractor is in ALR mode. The ALR mode is automatically disengaged when most of the webbing is retracted back onto the spool. The automatic locking mode must be used when installing a child safety seat in the front or rear passenger seating positions, where dual locking mode retractors are provided. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation > Dual Locking Mode Retractors > Page 6871 Seat Belt Retractor: Description and Operation Energy Management Retractor ENERGY MANAGEMENT RETRACTOR This vehicle has a safety belt system with an energy management feature at the front seating positions help further reduce the risk of injury in the event a head-on collision. The energy management retractor feature is designed to pay out webbing in a controlled manner. This feature is designed to help reduce the belt force acting on an occupant's chest. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation > Page 6872 Seat Belt Retractor: Testing and Inspection Functional Test - Retractor The safety belt retractor assembly must be freely operational for extraction and retraction of the safety belt webbing between full extension and in-vehicle stowed positions. 1. Extract and retract the safety belt between the full extension and stowed positions. 2. Verify the retractor operates without excessive effort or binding. 3. Install a new safety belt retractor and buckle if no obvious concerns are noticed and the complaint has been verified. Functional Test - Automatic Locking Retractor WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Position the seat back into the full up position. 2. Position the height adjuster (if equipped) in the full down or up position. 3. Latch the seat belt buckle and tongue assembly. 4. Pull the shoulder belt out until the ALR feature is activated. 5. NOTE: Some seat mounted safety belt retractors may exhibit a slow retraction speed condition. It is not necessary to replace the safety belt retractor for this condition. Refer to Safety Belt Cleaning, for the concern. Release the shoulder belt and allow it to retract until it stops. 6. Pull on the shoulder belt to check that the belt has remained in the ALR mode. If the belt is not locked, install a new safety belt assembly. 7. Unlatch the safety belt tongue from the buckle and allow the safety belt to retract to its stowed position. 8. Pull the shoulder belt to verify the retractor assembly has converted automatically out of the ALR mode. If the shoulder belt remains locked in the stowed position, install a new safety belt retractor assembly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) Seat Belt Retractor: Service and Repair Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) SAFETY BELT RETRACTOR - FRONT, WITH SEAT INTEGRATED RESTRAINTS (SIR) Exploded View Safety Belt - Front, With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6875 Safety Belt Buckle - Front, 20 Percent (Regular cab) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6876 Safety Belt - Front, 20 Percent (SuperCab and SuperCrew) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6877 Safety Belt - Front, Without Seat Integrated Restraints (SIR) (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6878 Safety Belt - Front, Without Seat Integrated Restraints (SIR) (Part 2) Removal and Installation WARNING: - After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. - Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the affected seat. 2. Remove the front seat backrest. 3. Push the 2 release tabs and remove the head restraint. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6879 4. CAUTION: Install new head restraint guides if the releasing tabs are damaged during removal. NOTE: The inboard and outboard head restraint guides are not interchangeable. Access and remove the 2 head restraint guides. Release the locking tabs and pull the head restraint guides out of the backrest frame tubes. 5. Detach the 2 safety belt tower screw covers. 6. Remove the 4 screws and the safety belt tower. 7. Remove the screw and separate the safety belt guide. 8. Lift the backrest trim cover material and release the J-clip. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6880 9. CAUTION: Use care when separating the seat backrest trim cover from the hook-and-loop strips, or the hook-and-loop strips can be torn from the backrest foam pad. Invert the backrest trim cover and remove the row of hog rings. Release the hook-and-loop strips and separate the backrest trim cover from the foam pad. 10. Remove the hog rings on the back of the backrest foam pad and remove the backrest trim cover. 11. Remove the backrest foam pad from the backrest frame. 12. Remove the safety belt retractor bolt and the safety belt retractor. - To install, tighten to 55 Nm (41 lb-ft). 13. Release the safety belt retractor upper guide from the backrest frame. 14. To install, reverse the removal procedure. 15. Install the front seat backrest. 16. Install the affected seat. 17. Check the active restraint system for correct operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6881 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Front, Center SAFETY BELT RETRACTOR - FRONT, CENTER Exploded View Safety Belt - Front, With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6882 Safety Belt Buckle - Front, 20 Percent (Regular cab) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6883 Safety Belt - Front, 20 Percent (SuperCab and SuperCrew) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6884 Safety Belt - Front, Without Seat Integrated Restraints (SIR) (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6885 Safety Belt - Front, Without Seat Integrated Restraints (SIR) (Part 2) Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6886 - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Remove the subwoofer enclosure, if equipped. - Disconnect the subwoofer electrical connector. - Remove the 4 subwoofer enclosure bolt caps. - Remove the 4 subwoofer enclosure bolts. - Remove the subwoofer enclosure. 2. Remove the back of cab panel insulator. - Remove the pushpins and release the retaining clips. - Remove the back of cab panel insulator. 3. Remove the D-ring bolt. - To install, tighten to 40 Nm (30 lb-ft). 4. Remove the safety belt retractor bolt and safety belt retractor. - To install, tighten to 48 Nm (35 lb-ft). 5. To install, reverse the removal procedure. 6. Check the active restraint system for correct operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6887 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Front, Without Seat Integrated Restraints (SIR) SAFETY BELT RETRACTOR - FRONT, WITHOUT SEAT INTEGRATED RESTRAINTS (SIR) Exploded View Safety Belt - Front, With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6888 Safety Belt Buckle - Front, 20 Percent (Regular cab) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6889 Safety Belt - Front, 20 Percent (SuperCab and SuperCrew) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6890 Safety Belt - Front, Without Seat Integrated Restraints (SIR) (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6891 Safety Belt - Front, Without Seat Integrated Restraints (SIR) (Part 2) Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Passenger retractor 1. When servicing the passenger safety belt retractor, depower the SRS. All retractors 2. Remove the front and rear door scuff plate. 3. Open the D-ring cover. 4. Remove the D-ring nut. - To install, tighten to 40 Nm (30 lb-ft). 5. Remove the B-pillar trim panel. Passenger retractor 6. Disconnect the belt tension sensor (BTS) electrical connector. All retractors 7. Remove the safety belt anchor bolt. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6892 - To install, tighten to 47 Nm (35 lb-ft). 8. Remove the safety belt retractor bolt and safety belt retractor. - To install, tighten to 47 Nm (35 lb-ft). 9. To install, reverse the removal procedure. Passenger retractor 10. Repower the SRS. All retractors 11. Check the active restraint system for correct operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6893 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Rear, Center SAFETY BELT RETRACTOR - REAR, CENTER Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6894 systems increases the risk of serious personal injury or death in a crash. 1. Remove the rear seat backrest. 2. Remove the rear center D-ring bolt and D-ring. - To install, tighten to 40 Nm (30 lb-ft). 3. Remove the back of the cab panel insulator. - Remove the pin-type retainers. - Release the retaining clips and remove the panel insulator. 4. NOTE: The LH safety belt buckle is attached to the safety belt and retractor assembly anchor. Remove the nut and rear center safety belt anchor and LH safety belt buckle. To install, tighten to 80 Nm (59 lb-ft). 5. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Remove the bolt and rear center safety belt retractor assembly. To install, tighten to 48 Nm (35 lb-ft). 6. To install, reverse the removal procedure. 7. Check the active restraint system for correct operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6895 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Rear SAFETY BELT RETRACTOR - REAR Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front, With Seat Integrated Restraints (SIR) > Page 6896 - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Remove the rear seat backrest and cushion. 2. Open the D-ring cover. 3. Remove the outboard D-ring bolt. - To install, tighten to 48 Nm (35 lb-ft). 4. Remove the rear outboard safety belt anchor bolt. - To install, tighten to 48 Nm (35 lb-ft). 5. Remove the C-pillar trim panel(s) and position aside. 6. Remove the bolt and rear outboard safety belt retractor. - To install, tighten to 48 Nm (35 lb-ft). 7. To install, reverse the removal procedure. 8. Check the active restraint system for correct operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tension Sensor > Component Information > Description and Operation Seat Belt Tension Sensor: Description and Operation BELT TENSION SENSOR (BTS) The safety belt tension sensor (BTS) is part of the passenger front outboard safety belt and retractor assembly and is not serviced separately. The safety BTS is located at the safety belt anchor point and is used in conjunction with the occupant classification sensor (OCS) system. Refer to Air Bag Systems. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations View 151-29 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Safety Belt Buckle Pretensioner, Driver C3201 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Safety Belt Buckle Pretensioner, Driver > Page 6905 C3202 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Safety Belt Buckle Pretensioner, Driver > Page 6906 C3238 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Safety Belt Buckle and Pretensioner Seat Belt Tensioner: Description and Operation Safety Belt Buckle and Pretensioner SAFETY BELT BUCKLE AND PRETENSIONER The safety belt buckle and pretensioner is a pyrotechnic device that removes excess webbing from the safety belt when deployed. The pretensioner works in conjunction with the front air bag system. When the pretensioners deploy, this causes the buckle to move downward, removing excess webbing from the lap and shoulder safety belts. If the vehicle is involved in a collision that results in deployment of the safety belt pretensioners, a new driver and passenger seat belt system (including safety belt buckle and pretensioners, safety belt retractors and height adjusters) must be installed. For safety belt buckle pretensioner diagnostic information, refer to Air Bag Systems. For safety belt buckle pretensioner disposal information, refer to Air Bag Systems. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Safety Belt Buckle and Pretensioner > Page 6909 Seat Belt Tensioner: Description and Operation Safety Belt Buckle and Pretensioners SAFETY BELT BUCKLE AND PRETENSIONERS As part of the supplemental restraint system (SRS), the driver and passenger front seat safety belt buckles are equipped with pretensioners. The safety belt buckle and pretensioners are attached to the seat tracks. The safety belt buckle and pretensioners remove excess slack from the safety belt webbing and are activated by the restraints control module (RCM) when the module detects a collision event force exceeding a programmed limit. For information or if a deployment has occurred, refer to the appropriate procedure in Air Bag Systems. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Page 6910 Seat Belt Tensioner: Service and Repair SAFETY BELT BUCKLE AND PRETENSIONER Exploded View Safety Belt - Front, With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Page 6911 Safety Belt Buckle - Front, 20 Percent (Regular cab) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Page 6912 Safety Belt - Front, 20 Percent (SuperCab and SuperCrew) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Page 6913 Safety Belt - Front, Without Seat Integrated Restraints (SIR) (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Page 6914 Safety Belt - Front, Without Seat Integrated Restraints (SIR) (Part 2) Removal and Installation WARNING: - After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. - Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the affected seat. 2. CAUTION: To prevent component damage and avoid setting diagnostic trouble codes (DTCs), the following precautions must be taken: - The position assurance locking wedge must be in the released position when inserting or removing the electrical connector from the safety belt buckle and pretensioner. - Do not install the electrical connector by pushing on the position assurance locking wedge. - Make sure the electrical connector and position assurance locking wedge are fully seated after connecting to the safety belt buckle and pretensioner. Release the locking wedge on the safety belt buckle and pretensioner electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Page 6915 3. Disconnect the safety belt buckle and pretensioner electrical connectors. 4. Remove the nut and safety belt buckle and pretensioner. - To install, tighten to 55 Nm (41 lb-ft). - The anti-rotation tab must be correctly aligned for correct installation. - When installing, pull the safety belt buckle through the anti-rattle retainer located on the side of the seat. 5. To install, reverse the removal procedure. 6. Check the active restraint system for correct operation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations View 151-2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6920 C177 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6921 Impact Sensor: Testing and Inspection IMPACT SENSORS WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. For this vehicle line, the SRS uses one satellite sensor in addition to the RCM. The RCM is mounted to the center tunnel beneath the 20 percent seat or floor console (if equipped). All vehicles have one front impact severity sensor located in the front-center area of the vehicle, behind the grille mounted on the lower radiator support. Mounting orientation is critical for correct operation of all impact sensors. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6922 Impact Sensor: Service and Repair FRONT IMPACT SEVERITY SENSOR Removal and Installation WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: - The supplemental restraint system (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Depower the SRS. 2. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. CAUTION: If the hood latch support bracket is damaged in any way that would affect the way the front impact severity sensor mounts to its original manufactured position, a new hood latch support bracket must be installed. NOTE: The front impact severity sensor is mounted to the hood latch support bracket. Remove the front impact severity sensor bolt. To install, tighten to 12 Nm (9 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6923 3. NOTE: Make sure the hood latch support bracket and front impact severity sensor mating surfaces are clean and free of foreign material. Remove the front impact severity sensor and disconnect the electrical connector. When installing the front impact severity sensor, align the locators on the front impact severity sensor to the holes of the hood latch bracket. 4. To install, reverse the removal procedure. 5. Repower the SRS. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger View 151-29 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 6928 View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver C3065 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 6931 C3066 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Tension Sensor > Component Information > Description and Operation Seat Belt Tension Sensor: Description and Operation BELT TENSION SENSOR (BTS) The safety belt tension sensor (BTS) is part of the passenger front outboard safety belt and retractor assembly and is not serviced separately. The safety BTS is located at the safety belt anchor point and is used in conjunction with the occupant classification sensor (OCS) system. Refer to Air Bag Systems. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations View 151-29 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Page 6938 C3042 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Page 6939 Seat Occupant Sensor: Description and Operation OCCUPANT CLASSIFICATION SENSOR (OCS) WARNING: Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. NOTE: - Occupant classification sensor (OCS) system components (set wiring harness, seat cushion frame, seat cushion foam pad, bladder with pressure sensor and occupant classification system module [OCSM]) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, an OCS system service kit (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness and OCSM) must be installed as an assembly. - To identify between a production OCS system and an OCS system service kit, inspect the OCSM electrical connector. A production OCS system allows the disconnection of the OCSM electrical connector. An OCS system service kit has the electrical connector glued to the OCSM, it cannot and should not be disconnected or altered. The OCS system is standard equipment on all front outboard passenger seats. For information on diagnosing or servicing the OCS system, refer to Air Bag Systems. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Page 6940 Seat Occupant Sensor: Service and Repair OCCUPANT CLASSIFICATION SENSOR Special Tool(s) Special Tool(s) Removal WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Page 6941 CAUTION: - While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - To prevent system failure, it is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. - Do not install a new heater mat on a front passenger seat cushion. If a new cushion heater mat is needed on the front passenger seat, an occupant classification sensor (OCS) service kit equipped with a heater mat must be installed. Failure to follow this instruction may result in incorrect operation of the OCS system. NOTE: - Occupant classification sensor (OCS) system components (seat wiring harness, seat cushion frame, seat cushion foam pad, bladder with pressure sensor and occupant classification system module [OCSM]) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, an OCS system service kit (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness and OCSM) must be installed as an assembly. - To identify between a production OCS system and an OCS service kit, inspect the OCSM electrical connector. A production OCS system allows the disconnect of the electrical connector from the OCSM. An OCS system service kit has the OCSM electrical connector glued to the module. It cannot and should not be disconnected or altered. - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Remove the passenger seat. 2. CAUTION: To prevent component damage and avoid setting DTCs, the following precautions must be taken when disconnecting the safety belt buckle pretensioner. The position assurance locking wedge must be in the released position when inserting or removing the electrical connector from the safety belt buckle and pretensioner. - Do not install the electrical connector by pushing on the position assurance locking wedge. - Make sure the electrical connector and position assurance locking wedge are fully seated after connecting to the safety belt buckle and pretensioner. Release the locking wedge on the safety belt buckle and pretensioner electrical connector. 3. Disconnect the safety belt buckle switch and pretensioner electrical connectors. 4. NOTE: Vehicles without seat integrated restraints (SIR) will have the belt tension sensor (BTS) connector at the B-pillar and will not have to be disconnected for this procedure. Disconnect the BTS electrical connector and route out the wire harness (vehicles with SIR only). 5. Remove the seat cushion nuts. 6. If equipped with manual lumbar, release the J-clip and route out the manual lumbar cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Page 6942 7. NOTE: Disconnect and release any remaining electrical connectors and pin-type retainers necessary to remove the seat cushion frame. Remove the seat cushion frame assembly. To aid in removal, recline the seat. - Remove the safety belt buckle from the seat cushion strap. 8. Release the seat cushion trim cover J-clips and pin-type retainers from the seat cushion frame. 9. At the front outboard side of the seat cushion frame, pull the trim cover back and release the 2 remaining clips. 10. Remove all the hog rings and separate the trim cover from the foam pad of the OCS assembly. Installation CAUTION: - While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - To prevent system failure, it is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. - Do not install a new heater mat on a front passenger seat cushion. If a new cushion heater mat is needed on the front passenger seat, an occupant classification sensor (OCS) service kit equipped with a heater mat must be installed. Failure to follow this instruction may result in incorrect operation of the OCS system. NOTE: OCS system components (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness and OCSM) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or cushion foam pad are needed, an OCS system service kit (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness and OCSM) must be installed as an assembly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Page 6943 1. Install the seat cushion trim cover. - Install hog rings to attach the seat cushion trim cover to the seat cushion foam pad of the OCS assembly at all locations from where they were removed. 2. At the front outboard side of the seat cushion frame, attach the 2 clips. 3. On vehicles equipped with SIR seats, attach the seat cushion trim cover J-clips to the seat cushion frame. - If equipped with manual lumbar, do not attach the rear inboard J-clip at this time. 4. Install the seat cushion assembly and the 4 nuts to the seat track. - Position the safety belt buckle through the seat cushion strap. - Tighten to 25 Nm (18 lb-ft). 5. If equipped, connect the backrest heated seat element electrical connector and attach any wire harness retainers to the seat cushion frame. 6. If equipped, connect the power seat track electrical connector and attach any wire harness retainers to the seat cushion frame. 7. NOTE: If equipped with manual lumbar, make sure this wire harness is routed above the manual lumbar cable. Connect the safety belt buckle pretensioner and safety belt buckle switch electrical connectors and attach the wire harness retainer to the seat track. 8. CAUTION: To prevent component damage and avoid setting DTCs, the following precautions must be taken: - The position assurance locking wedge must be in the released position when inserting the electrical connector in the safety belt buckle and pretensioner. - Do not install the electrical connector by pushing on the position assurance locking wedge. - Make sure the electrical connector and position assurance locking wedge are fully seated after connecting to the safety belt buckle and pretensioner. Fully engage the locking wedge on the safety belt buckle and pretensioner electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Page 6944 9. On vehicles with SIR seats, connect the BTS electrical connector. - Route the wire harness and connect the electrical connector. 10. If equipped, connect the manual lumbar cable. - Route the cable and attach the J-clip. 11. Install the passenger seat. Do not prove the SRS at this time. - Make sure the safety belts and buckles accessible to the occupants after installation. - Verify the safety belt retractor operates without excessive effort or binding. 12. WARNING: - Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. - Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. CAUTION: To prevent system failure, it is necessary to carry out the occupant classification sensor (OCS) system reset of the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed or an OCS system service kit is installed. A scan tool is used to trigger the command to carry out the OCS system reset. - To prevent system failure, the following precautions must be taken before carrying out the occupant classification sensor (OCS) system reset: Make sure the voltage to the occupant classification system module (OCSM) is above 8.0 volts and less than 18.0 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. NOTE: If the first attempt to carry out the OCS system reset is unsuccessful, a second attempt must be made. If the second attempt to carry out the OCS system reset is unsuccessful, a new OCS system service kit must be installed. Carry out the OCS system reset command using the scan tool. 13. Cycle the ignition switch from ON to OFF. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Page 6945 14. NOTE: The ignition switch must be cycled after the OCS system reset. Cycle the ignition switch from OFF to ON. 15. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. 16. NOTE: A prepaid return postcard is provided with a new OCS service kit. The serial number for the new part and the vehicle identification number (VIN) must be recorded and sent to Ford Motor Company. When installing a new OCS service kit, fill out the necessary information on the OCS service kit traceability card and return it along with the complete inoperative OCS system to Ford Motor Company. When returning the inoperative OCS system, include the following: seat cushion foam pad, seat cushion frame, bladder, OCSM, pressure sensor (transducer), hose, electrical connectors and wire harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 6949 C356 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Position Sensor - Manual Seat Track Seat Position Sensor: Service and Repair Seat Position Sensor - Manual Seat Track SEAT POSITION SENSOR - MANUAL SEAT TRACK Removal and Installation WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Depower the SRS. 2. Disconnect the seat position sensor electrical connector. 3. Remove the nut and seat position sensor. - To install, tighten to 8 Nm (71 lb-in). 4. To install, reverse the removal procedure. 5. Repower the SRS. - After installation and power is restored, position the driver seat from its forward most position to its rearmost position and then back again. While positioning the seat, make sure that the seat position sensor and bracket and the wire harness do not come in contact with any other part of the seat that may cause damage. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Position Sensor - Manual Seat Track > Page 6952 Seat Position Sensor: Service and Repair Seat Position Sensor - Power Seat Track SEAT POSITION SENSOR - POWER SEAT TRACK Removal and Installation WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. NOTE: The seat position sensor is mounted at the LH rear of the seat track. Position the driver seat rearward enough so that upon removal the sensor can clear the bracket. Position the driver seat to access the seat position sensor. 2. Depower the SRS. 3. Fold the seat backrest all the way forward. 4. Disconnect the seat position sensor electrical connector. 5. Remove the nuts and seat position sensor. - To install, tighten to 8 Nm (71 lb-in). 6. To install, reverse the removal procedure. 7. Repower the SRS. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Position Sensor - Manual Seat Track > Page 6953 - After installation and power is restored, position the driver seat from its forward most position to its rearmost position and then back again. While positioning the seat, make sure that the seat position sensor, bracket and wire harness do not come in contact with any other part of the seat that may cause damage. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 6959 Accessory Delay Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 6960 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna - Satellite Radio Antenna: Service and Repair Antenna - Satellite Radio ANTENNA - SATELLITE RADIO Removal and Installation 1. Remove the RH A-pillar trim panel. 2. Remove the 3 screws, the RH sun visor retaining clip, and the RH sun visor. - If equipped, disconnect the electrical connector. 3. Lower the front of the headliner enough to gain access to the satellite radio antenna electrical connector. 4. NOTE: Remove the satellite antenna and pigtail through the mounting opening in the roof panel. Remove the satellite antenna. Disconnect the electrical connector. - Compress the tabs and release the satellite antenna from the roof panel. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna - Satellite Radio > Page 6965 Antenna: Service and Repair Antenna Base ANTENNA BASE Removal and Installation 1. Lower the glove compartment. - Press the side tabs and release the glove compartment. 2. Disconnect the antenna lead-in cable from the antenna cable. - Push the antenna cable end and the grommet through the side cowl. 3. Remove the antenna mast. 4. NOTE: A new antenna base cap must be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna - Satellite Radio > Page 6966 Remove the antenna base cap. 5. Remove the RH front fender splash shield. 6. Remove the 3 screws and the antenna base and cable assembly. 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna - Satellite Radio > Page 6967 Antenna: Service and Repair Antenna Cable - Satellite Radio ANTENNA CABLE - SATELLITE RADIO Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna - Satellite Radio > Page 6968 Removal and Installation Both cables 1. Press the tabs inward and lower the glove compartment completely. 2. Disconnect the upper-to-lower satellite radio antenna cable connection. Upper satellite radio antenna cable 3. Remove the RH A-pillar trim panel. 4. Remove the 3 screws, the RH sun visor retaining clip, and the RH sun visor. - If equipped, disconnect the electrical connector. 5. Lower the front of the headliner enough to gain access to the satellite radio antenna electrical connector. 6. Remove the upper satellite radio antenna cable. - Disconnect the electrical connector. - Separate the pushpins from the A-pillar and instrument panel. Lower satellite radio antenna cable 7. Remove the audio control module (ACM). 8. Remove the lower satellite radio antenna cable. - Disconnect the electrical connector. - Separate the pushpins from the instrument panel. Both cables 9. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna - Satellite Radio > Page 6969 Antenna: Service and Repair Antenna Lead-In Cable ANTENNA LEAD-IN CABLE Removal and Installation 1. Remove the audio control module (ACM). 2. Lower the glove compartment. - Press the side tabs and release the glove compartment. 3. Disconnect the antenna lead-in cable from the antenna cable. 4. Disconnect the pin-type retainers and remove the cable. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna - Satellite Radio > Page 6970 Antenna: Service and Repair Global Positioning System (GPS) Antenna GLOBAL POSITIONING SYSTEM (GPS) ANTENNA Removal and Installation 1. Remove the instrument cluster finish panel. 2. Remove the audio control module (ACM). 3. NOTE: Lift up on the RH side of the GPS antenna to disengage the clip. Remove the GPS antenna. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Vehicle Security Module (VSM) - Regular Cab Alarm Module: Service and Repair Vehicle Security Module (VSM) - Regular Cab VEHICLE SECURITY MODULE (VSM) - REGULAR CAB Removal CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage to the module may result. NOTE: - Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new vehicle security module (VSM) after installation. to carry out programmable module installation (PMI). - For the VSM to accept the PMI procedure, the following conditions must be met: a. the headlamp switch must be in the OFF position (must not be in the AUTOLAMP position, if equipped) b. the key must be in the ON position c. the driver door must be open d. the doors must be unlocked electronically by pressing the door lock control switch to the UNLOCK position momentarily Failure to follow this procedure will result in the PMI procedure to fail. - The tire pressure monitoring system (TPMS) functionality is integral to the VSM. - A new VSM is delivered in a "manufacturing mode" with 6 pre-set DTCs. These DTCs require that a successful configuration of the VSM occurs, then a successful TPMS sensor training occurs, then a successful self-test occurs, including the clearing of all DTCs. This is required in order to clear the 6 manufacturing mode DTCs. They are as follows: B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Vehicle Security Module (VSM) - Regular Cab > Page 6976 - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is only necessary if the VSM is being replaced. Upload the module configuration information from the VSM into the scan tool. 2. Turn the key to the OFF position. 3. Remove the LH B-pillar trim panel. 4. Disconnect the 2 VSM electrical connectors. 5. Remove the 2 screws and the VSM. Installation 1. NOTE: If it is necessary to install new VSM mounting screw J-clips, they are available using part number W520822. Position the VSM and install the 2 screws. Tighten to 7 Nm (62 lb-in). 2. Connect the 2 VSM electrical connectors. 3. NOTE: If the VSM is not being replaced, this is the last step that is necessary. Install the LH B-pillar trim panel. 4. NOTE: When successful, this step provides the calibration necessary for the VSM operation and clears DTC B2477. The clearing of the DTC indicates the calibration data has been successfully downloaded to the VSM. Download the VSM configuration information from the scan tool to the VSM. 5. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the VSM has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 6. NOTE: - DTC C2780 will not clear if any other DTCs are present in the VSM. - This step is required to clear DTC C2780, allow the VSM to exit the manufacturing mode, and to make sure there are no other concerns with the newly programmed VSM. Carry out the VSM on-demand self-test by clearing the DTCs and then retrieving the DTCs to confirm all DTCs have been cleared. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Vehicle Security Module (VSM) - Regular Cab > Page 6977 Alarm Module: Service and Repair Vehicle Security Module (VSM) - SuperCab and SuperCrew VEHICLE SECURITY MODULE (VSM) - SUPERCAB AND SUPERCREW Removal CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage to the module may result. NOTE: - Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new vehicle security module (VSM) after installation. to carry out programmable module installation (PMI). - For the VSM to accept the PMI procedure, the following conditions must be met: a. the headlamp switch must be in the OFF position (must not be in the AUTOLAMP position, if equipped) b. the key must be in the ON position c. the driver door must be open d. the doors must be unlocked electronically by pressing the door lock control switch to the UNLOCK position momentarily Failure to follow this procedure will result in the PMI procedure to fail. - The tire pressure monitoring system (TPMS) functionality is integral to the VSM. - A new VSM is delivered in a "manufacturing mode" with 6 pre-set DTCs. These DTCs require that a successful configuration of the VSM occurs, then a successful TPMS sensor training occurs, then a successful self-test occurs, including the clearing of all DTCs. This is required in order to clear the 6 manufacturing mode DTCs. They are as follows: B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Vehicle Security Module (VSM) - Regular Cab > Page 6978 - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is only necessary if the VSM is being replaced. Upload the module configuration information from the VSM into the scan tool. 2. Turn the key to the OFF position. 3. Remove the rear seat backrest. 4. If equipped, remove the rear interior trim panel. 5. Disconnect the 2 VSM electrical connectors. 6. Remove the 2 screws and the VSM. Installation 1. Position the VSM and install the 2 screws. - Tighten to 7 Nm (62 lb-in). 2. Connect the 2 VSM electrical connectors. 3. If equipped, install the rear interior trim panel. 4. NOTE: If the VSM is not being replaced, this is the last step that is necessary. Install the rear seat backrest. 5. NOTE: When successful, this step provides the calibration necessary for the VSM operation and clears DTC B2477. The clearing of the DTC indicates the calibration data has been successfully downloaded to the VSM. Download the VSM configuration information from the scan tool to the VSM. 6. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the VSM has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 7. NOTE: - DTC C2780 will not clear if any other DTCs are present in the VSM. - This step is required to clear DTC C2780, allow the VSM to exit the manufacturing mode, and to make sure there are no other concerns with the newly programmed VSM. Carry out the VSM on-demand self-test by clearing the DTCs and then retrieving the DTCs to confirm all DTCs have been cleared. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transmitter > Component Information > Service and Repair Alarm System Transmitter: Service and Repair PASSIVE ANTI-THEFT SYSTEM (PATS) TRANSCEIVER Removal and Installation 1. Remove the steering wheel. 2. Remove the 2 bolts and the lower steering column shroud. 3. NOTE: Vehicles with a steering column shift are shown; the floor console shift is similar. Remove the ignition lock cylinder cover. 4. Disconnect the passive anti-theft system (PATS) transceiver electrical connector. 5. Remove the screw and the PATS transceiver. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transmitter > Component Information > Service and Repair > Page 6982 6. NOTE: Replacement of the PATS transceiver does not require the PATS keys to be programmed into the PCM again. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Locations > Page 6986 C252 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams C500 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Testing and Inspection > Keyless Entry Keypad Code Programming Keyless Entry Key-Pad: Testing and Inspection Keyless Entry Keypad Code Programming KEYLESS ENTRY KEYPAD CODE PROGRAMMING 1. NOTE: The permanent factory keyless entry keypad code cannot be erased. Enter the permanent factory keyless entry keypad code. 2. Press the 1/2 button within 5 seconds to activate the programming mode. Holding the 1/2 button for more than 2 seconds after activation erases the stored customer code. The door locks lock, then unlock, confirming the code is erased. The existing code does not need to be erased to program a new customer code. 3. Within 5 seconds, enter the new 5-digit keyless entry keypad code. The door locks lock and unlock to confirm the new customer code is programmed. 4. To exit the programming mode, wait 5 seconds. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Testing and Inspection > Keyless Entry Keypad Code Programming > Page 6993 Keyless Entry Key-Pad: Testing and Inspection Perimeter Lighting Feature Programming PERIMETER LIGHTING FEATURE PROGRAMMING Programming the Perimeter Lighting Feature Using the Door Lock Control Switch NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the RUN position. 2. Press the unlock button on the door unlock control 3 times. 3. Turn the ignition switch from the RUN to the OFF position. 4. Press the unlock button on the door unlock control switch 3 times. 5. Turn the ignition switch to the RUN position. The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The unlock button must be pressed twice within 5 seconds. Within 30 seconds of entering the programming mode, press the unlock button on the door lock control switch twice to enable/disable the perimeter lighting feature. The horn chirps once if the perimeter lighting is disabled or a chirp followed by a honk if the perimeter lighting is enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Testing and Inspection > Page 6994 Keyless Entry Key-Pad: Service and Repair KEYLESS ENTRY KEYPAD Removal and Installation 1. Remove the exterior front door handle. 2. Release the locking tabs and remove the keyless entry keypad. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6998 View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6999 Keyless Entry Module: Diagrams C3008A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7000 C3008B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate Keyless Entry Transmitter: Customer Interest Keyless Entry - Transmitter May Not Operate TSB 08-12-9 06/23/08 INOPERATIVE RKE TRANSMITTER (KEY FOB) - DISCHARGED KEY FOB BATTERY FORD: 2008 Crown Victoria, Focus, Mustang 2007-2008 F-150 2008 E-Series, Expedition, Explorer Sport Trac, Explorer, F-Super Duty, Ranger LINCOLN: 2007-2008 Mark LT MERCURY: 2008 Grand Marquis, Mountaineer ISSUE Some 2007-2008 vehicles equipped with a remote keyless entry (RKE) transmitter may exhibit an inoperative Key Fob due to a discharged Key Fob battery. This may be caused by an internal issue with the Key Fob software. This concern only applies to vehicles built within a specific date range with Key Fobs manufactured within a specific date range. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE PERFORMING THIS PROCEDURE WILL HAVE NO EFFECT ON KEY FOB RANGE. REFER TO WORKSHOP MANUAL (WSM), SECTION 501-14 FOR KEY FOB RANGE DIAGNOSTICS. 1. Refer to vehicle list for build date range. (Figure 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 7009 a. If the vehicle was built within the date range, then continue with this procedure. b. If not, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 2. Is the vehicle Key Fob part number 8L3T-15K601-AA (3 button) or 8S4T-15K601-AA (4 button)? (Figure 2) a. Yes - Go to Step 3. b. No - Do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 3. Using a thin coin, open the Key Fob and inspect manufacturer's date code sticker. The first three digits = day of year. The last digit = year. (Figure 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 7010 a. If the first 3 digits are equal to or between 005 and 306 (5th day through 306th day) and the last digit is 7 (year), then proceed to Step 4. b. If the number is outside this specified range, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 4. If the Key Fob is inoperative due to a discharged Key Fob battery, and the date code falls within the specified range, then replace Key Fob. Program the new Key Fob transmitter using the IDS RKE Transmitter Programming Procedure. Reassemble old Key Fob for warranty return analysis. NOTE KEY FOBS REPLACED UNDER WARRANTY WILL BE REQUESTED FOR ANALYSIS AND VERIFICATION OF THE DATE CODE. a. IDS RKE Transmitter Programming Procedure (1) Install known good battery into the suspect Key Fob so that IDS scan tool can identify it. (2) Connect IDS to vehicle. (3) From the Main Toolbox tab: (a) Select - Body. (b) Select - Security. (c) Select - Remote Keyless Entry. (4) Press the "Unlock" button on the suspect Key Fob to view the Transmitter Identification Code (TIC) in IDS. 5. Select "Erase One Key Fob" or the "Erase" button. 6. Select the suspect Key Fob TIC to erase from vehicle memory. 7. Remove battery from suspect Key Fob and reassemble for warranty return. 8. Select "Reprogram a New Keyfob" or the "Program" button. 9. Press the "Unlock" button on the NEW Key Fob. 10. Follow the instructions on the scan tool screen to complete the programming procedure. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081209A 2008 Focus, Mustang, 0.3 Hr. Explorer, Explorer Sport Trac, Mountaineer, E-Series, Expedition, Crown Victoria, Grand Marquis, Ranger, F-Super Duty: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify Date Code Sticker (Do Not Use With 15601A) 081209A 2007-2008 F-150, Mark 0.3 Hr. LT: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify Date Code Sticker (Do Not Use With 15601A) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 7011 DEALER CODING CONDITION BASIC PART NO. CODE 15K601 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter May Not Operate TSB 08-12-9 06/23/08 INOPERATIVE RKE TRANSMITTER (KEY FOB) - DISCHARGED KEY FOB BATTERY FORD: 2008 Crown Victoria, Focus, Mustang 2007-2008 F-150 2008 E-Series, Expedition, Explorer Sport Trac, Explorer, F-Super Duty, Ranger LINCOLN: 2007-2008 Mark LT MERCURY: 2008 Grand Marquis, Mountaineer ISSUE Some 2007-2008 vehicles equipped with a remote keyless entry (RKE) transmitter may exhibit an inoperative Key Fob due to a discharged Key Fob battery. This may be caused by an internal issue with the Key Fob software. This concern only applies to vehicles built within a specific date range with Key Fobs manufactured within a specific date range. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE PERFORMING THIS PROCEDURE WILL HAVE NO EFFECT ON KEY FOB RANGE. REFER TO WORKSHOP MANUAL (WSM), SECTION 501-14 FOR KEY FOB RANGE DIAGNOSTICS. 1. Refer to vehicle list for build date range. (Figure 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 7017 a. If the vehicle was built within the date range, then continue with this procedure. b. If not, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 2. Is the vehicle Key Fob part number 8L3T-15K601-AA (3 button) or 8S4T-15K601-AA (4 button)? (Figure 2) a. Yes - Go to Step 3. b. No - Do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 3. Using a thin coin, open the Key Fob and inspect manufacturer's date code sticker. The first three digits = day of year. The last digit = year. (Figure 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 7018 a. If the first 3 digits are equal to or between 005 and 306 (5th day through 306th day) and the last digit is 7 (year), then proceed to Step 4. b. If the number is outside this specified range, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 4. If the Key Fob is inoperative due to a discharged Key Fob battery, and the date code falls within the specified range, then replace Key Fob. Program the new Key Fob transmitter using the IDS RKE Transmitter Programming Procedure. Reassemble old Key Fob for warranty return analysis. NOTE KEY FOBS REPLACED UNDER WARRANTY WILL BE REQUESTED FOR ANALYSIS AND VERIFICATION OF THE DATE CODE. a. IDS RKE Transmitter Programming Procedure (1) Install known good battery into the suspect Key Fob so that IDS scan tool can identify it. (2) Connect IDS to vehicle. (3) From the Main Toolbox tab: (a) Select - Body. (b) Select - Security. (c) Select - Remote Keyless Entry. (4) Press the "Unlock" button on the suspect Key Fob to view the Transmitter Identification Code (TIC) in IDS. 5. Select "Erase One Key Fob" or the "Erase" button. 6. Select the suspect Key Fob TIC to erase from vehicle memory. 7. Remove battery from suspect Key Fob and reassemble for warranty return. 8. Select "Reprogram a New Keyfob" or the "Program" button. 9. Press the "Unlock" button on the NEW Key Fob. 10. Follow the instructions on the scan tool screen to complete the programming procedure. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081209A 2008 Focus, Mustang, 0.3 Hr. Explorer, Explorer Sport Trac, Mountaineer, E-Series, Expedition, Crown Victoria, Grand Marquis, Ranger, F-Super Duty: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify Date Code Sticker (Do Not Use With 15601A) 081209A 2007-2008 F-150, Mark 0.3 Hr. LT: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify Date Code Sticker (Do Not Use With 15601A) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 7019 DEALER CODING CONDITION BASIC PART NO. CODE 15K601 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry Transmitter Programming Keyless Entry Transmitter: Testing and Inspection Remote Keyless Entry Transmitter Programming REMOTE KEYLESS ENTRY TRANSMITTER PROGRAMMING NOTE: - All remote keyless entry (RKE) transmitters must be programmed at the same time. - Programming of the RKE transmitters can be accomplished using a scan tool or by carrying out the following steps: 1. The vehicle must be electronically unlocked before entering program mode using the RKE transmitter, keyless entry keypad (if equipped) or door lock control switch while the driver door is open. 2. Turn the key from OFF to RUN 8 times within 10 seconds, with the eighth turn ending in RUN. If the module successfully enters the program mode, it locks and then unlocks all doors. 3. Within 20 seconds, press any button on an RKE transmitter, and the doors lock and then unlock to confirm that each RKE transmitter is programmed. Repeat this step for each RKE transmitter. 4. If the door locks do not respond for any RKE transmitter, wait several seconds and press the button again. If the door locks still fail to respond, refer to Inspection and Verification. Make sure that no more than the maximum number (4) of RKE transmitters are attempted to be programmed. See: Body and Frame/Locks/Power Locks/Testing and Inspection/Initial Inspection and Diagnostic Overview/Inspection and Verification 5. Exiting the programming mode is accomplished if one of the following occurs: - The key transitions to the OFF position. Twenty seconds have passed since entering programming mode or since the last RKE transmitter was programmed. - The maximum number (4) of RKE transmitters have been programmed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry Transmitter Programming > Page 7022 Keyless Entry Transmitter: Testing and Inspection Autolock and Horn Chirp Programming AUTOLOCK AND HORN CHIRP PROGRAMMING Using the Keyless Entry Keypad NOTE: - The autolock feature is not available on vehicles equipped with manual transmissions. - A manual enable/disable mode allows the autolock feature to be turned off and on. 1. Enter the 5-digit permanent entry code into the keyless entry keypad. 2. Within 5 seconds of entering the code, press and hold the 7/8 button on the keypad. 3. Within 5 seconds of Step 2, and while holding the 7/8 button, press the 3/4 button on the keypad and release it. 4. NOTE: If the autolock feature is disabled, the horn chirps once. If the autolock feature is enabled, the horn chirps once shortly then sounds a second time for a longer sound of the horn once the above sequence is completed. Within 5 seconds of Step 3, release the 7/8 button on the keypad. Using the Ignition Lock Cylinder NOTE: The autolock feature is not available on vehicles equipped with manual transmissions. 1. Close all the doors. 2. Confirm that the ignition switch is in the OFF position. 3. Turn the ignition switch from OFF to ON. 4. NOTE: Steps 4 through 8 must be carried out within 30 seconds. Press the door lock control switch UNLOCK button 3 times. 5. Turn the ignition switch from ON to OFF. 6. Press the door lock control switch UNLOCK button 3 times. 7. Turn the ignition switch from OFF to ON. 8. Verify that the horn chirps. This indicates the system is in the enable/disable mode and is ready to accept program changes. 9. Press the door lock control switch UNLOCK button one time to toggle the autolock/relock feature OFF. 10. Press the door lock control switch LOCK button once to enter the command. 11. Verify that the horn chirps 1 time. There should only be 1 chirp indicating that autolock/relock feature is disabled. If 1 chirp is heard, followed by a longer sound of the horn, the autolock/relock feature has been enabled. Return to Step 9. 12. Turn the ignition switch to the OFF position to exit the enable/disable mode. 13. Exit the vehicle and verify that the horn chirps once to indicate that a feature has been changed and that autolock/relock is disabled. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Procedures Keyless Entry Transmitter: Procedures Remote Memory Activation REMOTE MEMORY ACTIVATION 1. Position the driver seat and pedals to the desired position. 2. Press the set button on the memory set switch. 3. Within 5 seconds, press the 1 or 2 button on the memory set switch. This stores the configuration for driver 1 or driver 2. 4. Press the set button. 5. Within 5 seconds, press any button on the remote keyless entry (RKE) transmitter and then press the 1 or 2 button on the driver door panel to associate the RKE transmitter with position. 6. If a second memory setting is desired, repeat the procedure with the second RKE transmitter. Remote Memory Deactivation REMOTE MEMORY DEACTIVATION 1. Press the set button on the memory set switch. 2. Within 5 seconds, press any button on the remote keyless entry (RKE) transmitter that you wish to deactivate and then press the set button on the memory set switch. 3. If a second memory setting desired to be deactivated, repeat the procedure with the second RKE transmitter. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Procedures > Page 7025 Keyless Entry Transmitter: Removal and Replacement TAILGATE LATCH REMOTE CONTROL Exploded View Removal and Installation 1. Open and support the tailgate. 2. Remove the 8 screws and the tailgate access panel. - To install, tighten to 5 Nm (44 lb-in). 3. Open the 2 clips and release the 2 tailgate latch actuating rods from the tailgate remote control. 4. Release the 2 tailgate latch actuating rod locators from the tailgate. 5. Remove the 2 nuts and the tailgate remote control. - To install, tighten to 7 Nm (62 lb-in). 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: Customer Interest SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: All Technical Service Bulletins SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 7040 Communications Control Module: Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 7041 View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 7042 Communications Control Module: Diagrams C290A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 7043 C290B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 7044 C290C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 7045 Communications Control Module: Service and Repair AUDIO CONTROL MODULE (ACM) Removal and Installation NOTE: - If installing a new navigation audio control module (ACM), remove the navigation DVD if possible, before sending the ACM to an authorized audio system repair facility. - It is not necessary to remove the ACM to retrieve the part number. 1. Remove the instrument panel center finish panel. - Disconnect the electrical connectors. 2. Remove the 4 screws and the ACM. - Disconnect the electrical connectors and the antenna cable. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 7050 C2023 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 7051 Parking Assist Control Module: Service and Repair PARKING AID MODULE Removal and Installation 1. If replacing the parking aid speaker only, proceed as follows: - Disconnect the parking aid speaker electrical connector. - Disengage the parking aid speaker retaining clips. - Remove the parking aid speaker. 2. If replacing the parking aid module (PAM), proceed as follows: - Disconnect the electrical connectors. - Remove the PAM nuts. - Remove the PAM. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 7052 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left C4009 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 7058 C4011 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 7059 C4010 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 7060 C4012 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 7061 Parking Assist Distance Sensor: Service and Repair PARKING AID SENSOR Removal 1. Disconnect the parking aid sensor electrical connector. 2. Press the retaining tabs to remove the parking aid sensor. - Remove the parking aid sensor from the rear bumper. Installation 1. To install the parking aid sensor in the rear bumper, insert the sensor in the opening until the retaining tabs lock in position. 2. Connect the parking aid sensor electrical connector. 3. After installing the sensor(s), use the scan tool to verify that the parking aid sensor PIDs read no object present and that the parking aid sensor attenuation PIDs read between 0-16 ms. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Switch > Component Information > Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Switch > Component Information > Locations > Page 7065 C2035 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Switch > Component Information > Locations > Page 7066 Parking Assist Switch: Service and Repair PARKING AID SWITCH Removal and Installation 1. Remove the instrument panel center finish panel. 2. Press the retaining tabs to remove the parking aid switch. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Diagrams C2024 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Diagrams C4357 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 7076 C253 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 7077 Driver/Vehicle Information Display: Description and Operation INFORMATION AND MESSAGE CENTER Message Center The message center is a fixed format display that is controlled by the message center switches. The message center is located in the lower RH corner of the instrument cluster and displays important vehicle information by constantly monitoring different vehicle systems. The message center may display a warning message pertaining to the system in which a fault has been detected. The message center provides the following features: Information menu - Setup menu - Warning messages The message center information can be selected through a set of 3 buttons: INFO - RESET - SETUP The setup display time-outs and defaults to the blank display function. The temporary alert display interrupts the current display to show the status of an event that has just happened. The warning display interrupts the current display until cleared or reset by the driver. Compass Display The message center provides a compass display and uses directional information sent from the compass module. The compass module is mounted to the underside of the interior rear view mirror or integrated into the mirror if equipped with a auto-dimming mirror or a rear video camera display mirror. Information Displays The information displays are non-timed modes. The selected mode remains on until the driver presses a message center button to change the mode, or it is overridden by another mode. The information display modes are: Odometer - Trip odometer - Compass - Outside air temperature - Distance to empty - Average fuel economy - Elapsed trip time Setup Displays The setup displays are timed modes and default back to the blank display function. The setup display modes are: System check - English/metric units - Autolocks on, autolocks off - Language (English, French or Spanish) System Check Displays The system check function monitors a variety of systems and displays an OK message or warning message if a fault is detected in the monitored system. The systems monitored are as follows: Fuel level - Engine temperature - Oil pressure - Brake fluid level - Charging system Warning Messages The warning messages can interrupt the display until cleared or reset by the driver. The system uses 3 types of warning messages: single cycle, non-renewable, and repetitive. The single cycle of warning messages display once whenever the ignition switch is turned to the ON position or a fault occurs in a system. They can be cleared by pressing the RESET button. The single cycle warning message is: DOOR AJAR The non-renewable warning messages are displayed at a fixed interval whenever the ignition switch is turned to the ON position or is in the ACC position. To remove a repetitive warning message, press the RESET button. The message only recurs after 10 minutes or when the warning condition is corrected. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 7078 The non-renewable warning messages are: LOW FUEL LEVEL - CHECK CHARGING SYSTEM - CHECK TRACTION CONTROL - LOW BRAKE FLUID - LOW OIL PRESSURE - CHECK ENGINE TEMPERATURE - REDUCED ENGINE POWER - STOP ENGINE SAFELY The repetitive warning messages display whenever the ignition switch is turned to the ON position and a fault occurs in a system. The fault must be corrected to clear the warning messages. The repetitive warning messages are: CHECK FUEL CAP - TRANSMISSION - LOW TIRE PRESSURE - TIRE PRESSURE MONITOR FAULT - TIRE PRESSURE SENSOR FAULT Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Driver/Vehicle Information Display: Initial Inspection and Diagnostic Overview Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the data link connector (DLC). 5. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to diagnose no communication with the scan tool. 6. If the scan tool does not communicate with the vehicle: - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus (Module Communications Network) to diagnose no response from the PCM. 7. Carry out the network test. - If the scan tool responds with no communication for one or more modules, refer to Information Bus (Module Communications Network). - If the network test passes, retrieve and record the continuous memory DTCs. 8. Clear the continuous DTCs and carry out the self-test diagnostics for the PCM and the instrument cluster (IC). 9. If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to Body Control Systems (Multifunction Electronic Control Module). See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Trouble Code Descriptions/Information and Message Center 10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Principles of Operation PRINCIPLES OF OPERATION The message center is an integral part of the instrument cluster (IC) that receives and acts upon much of the same information that is input and used to operate the instrument cluster (IC) gauges, informational indicators, and warning indicators. The message center, located in the instrument cluster (IC) is a vacuum fluorescent 2-line display. The message center electronic functions use both hardwired and the network communication circuitry to transmit and receive information. Whenever conditions are present that require a warning message, the message center replaces the last selected display with the new warning display. Warning messages are generally associated with other observable instrument cluster (IC) indications. For example, when a door is opened, the message center displays the message DOOR AJAR along with the door ajar warning indicator. This allows the message center to be a more informative supplement to the instrument cluster (IC) gauges and indicators. It is very important to understand: - where the input (command) originates. - all the information (messages) necessary in order for a feature to operate. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7081 - which module(s) receive(s) the input or command message. - if the module that received the input (message) controls the output of the feature, or if it outputs a message over the CAN to another module. - which module controls the output of the feature. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7082 Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7083 Symptom Chart (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7084 Symptom Chart (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7085 Symptom Chart (Part 4) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7086 Driver/Vehicle Information Display: Pinpoint Tests Test A: The Message Center Is Not Operating Correctly PINPOINT TEST A: THE MESSAGE CENTER IS NOT OPERATING CORRECTLY Normal Operation The message center display is integrated into the lower RH corner of the instrument cluster (IC). The instrument cluster (IC) odometer, trip odometer, compass, outside air temperature and message center displays are contained in the same window. The message center switch is hardwired to the instrument cluster (IC) through circuits 1411 (GY/OG) and 1396 (VT/WH). The message center switches use a different resistance value for each switch, allowing the instrument cluster (IC) to determine which switch is pressed. This pinpoint test is intended to diagnose the following: - Instrument cluster (IC) - Message center switch A1-A3 Test B: The Message Center Switch Does Not Operate Correctly PINPOINT TEST B: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY Normal Operation The message center functionality is controlled through the message center switch, which is hardwired to the instrument cluster (IC) through the input circuit 1411 (GY/OG) and the return circuit 1396 (VT/WH). There are 3 message center switch buttons with each button operating a switch that uses different resistance values. The instrument cluster (IC) sends out a reference voltage to the message center switch on the input circuit and monitors the voltage drop when a message center switch button is pressed. The voltage drop will vary depending upon the resistance of each button, providing a specific indication to the instrument cluster (IC) which switch is pressed. - DTC B1209 (EIC Switch-2 Assembly Circuit Failure) - sets on-demand in the instrument cluster (IC) if any of the buttons on the message center are stuck or pressed during the self-test. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Instrument cluster (IC) - Message center switch Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7087 B1-B4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7088 B4-B6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7089 B6-B7 Test C: The Compass Is Inoperative PINPOINT TEST C: THE COMPASS IS INOPERATIVE Normal Operation The compass module (without auto-dimming interior rear view mirror) or interior rear view mirror (with auto-dimming interior rear view mirror) receives voltage from the central junction box (CJB) through circuit 294 (WH/LB) and is grounded through circuit 875 (BK/LB). The compass module (without auto-dimming interior rear view mirror) or interior rear view mirror (with auto-dimming interior rear view mirror) communicates vehicle direction to the instrument cluster (IC) to be displayed in the message center. The compass module (without auto-dimming interior rear view mirror) or interior rear view mirror (with auto-dimming interior rear view mirror) uses circuits 702 (WH/BK) and 703 (WH/OG) to communicate to the instrument cluster (IC). - DTC U2013 (Compass Module is Not Responding) - is a continuous memory DTC that sets in the instrument cluster (IC) if the compass module (without auto-dimming interior rear view mirror) or interior rear view mirror (with auto-dimming interior rear view mirror) does not send the compass data to the instrument cluster (IC). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Compass module (without auto-dimming mirror) - Interior rear view mirror (with auto-dimming mirror) - Instrument cluster (IC) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7090 C1-C2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7091 C2-C4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7092 C4-C6 Test D: The Compass Is Inaccurate PINPOINT TEST D: THE COMPASS IS INACCURATE Normal Operation The compass module (without auto-dimming interior rear view mirror) or interior rear view mirror (with auto-dimming interior rear view mirror) communicates vehicle direction to the instrument cluster (IC) to be displayed in the message center through circuits 702 (WH/BK) and 703 (WH/OG). The magnetic fields generated by the earths north and south poles are divided into zones that differ from each other with respect to how the magnetic fields appear. The magnetic north can change by up to 4 degrees between zones and become noticeable across multiple zones. The compass zone must be set to the correct zone for the compass to read accurately. Factors within the vehicle may affect the ability of the compass module to accurately read the magnetic north. Calibrating the compass allows the compass module to compensate for vehicle factors that influence the accuracy of the compass. NOTE: Outside factors such as bridges, steel structures, tall buildings and power lines also affect compass accuracy. This pinpoint test is intended to diagnose the following: - Compass zone setting - Compass calibration Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7093 - Vehicle magnetization - Compass module (without auto-dimming mirror) - Interior rear view mirror (with auto-dimming mirror) D1-D2 Test E: The Transmission Message Is Inoperative PINPOINT TEST E: THE TRANSMISSION MESSAGE IS INOPERATIVE Normal Operation The instrument cluster (IC) and message center receive transmission data from the PCM over the high speed controller area network (HS-CAN) communication bus. When a concern exists with the transmission, the PCM provides a command signal to the message center to display the transmission warning message. This pinpoint test is intended to diagnose the following: - Instrument cluster (IC) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7094 E1-E2 Test F: The Check Fuel Cap Message Is Inoperative/Always Displayed PINPOINT TEST F: THE CHECK FUEL CAP MESSAGE IS INOPERATIVE/ALWAYS DISPLAYED Normal Operation The PCM monitors the fuel tank evaporative emission system for significant leaks that occur following refueling of the vehicle. Once the PCM detects a fuel vapor leak, the PCM sends the instrument cluster (IC) a network message over the communication network to turn on the check fuel cap warning message display. DTC P0457 sets in the PCM following a successful cruise test, which is initiated when the vehicle is driven at a steady speed above 64 km/h (40 mph) for a duration of approximately 4-5 minutes. If the PCM is unable to successfully run the cruise test, the instrument cluster (IC) does not receive the check fuel cap network message and the check fuel cap message display remains off. - DTC P0457 (Evaporative Emission System Leak Detected) (fuel cap loose/off) - sets in the PCM if a fuel tank pressure change greater than -23.7 kPa (-7 in-Hg) of vacuum within 30 seconds after refueling occurs, or there is an excessive purge (fuel vapor) flow of greater than 454 g (1.0 lb) per minute. This pinpoint test is intended to diagnose the following: - PCM - Instrument cluster (IC) F1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7095 F2-F3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Page 7096 Driver/Vehicle Information Display: Service and Repair MESSAGE CENTER SWITCH Removal and Installation 1. Remove the message center switch. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Page 7097 Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Diagrams C2362 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Diagrams > Page 7102 Auxiliary Input / Output Jack: Service and Repair AUDIO INPUT JACK Removal and Installation 1. Remove the instrument panel center finish panel. 2. Remove the 2 screws and the instrument panel upper tray. - Disconnect the audio input jack electrical connector. 3. Release the tabs and remove the audio input jack. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Locations View 151-35 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Locations > Page 7106 C949 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Panel > Component Information > Service and Repair Entertainment System Control Panel: Service and Repair REAR ENTERTAINMENT MODULE (RETM) Removal and Installation NOTE: Programmable module installation (PMI) only needs to be carried out if the DVD player is being replaced. 1. Upload the DVD player configuration to the scan tool. 2. NOTE: Open the display to access the screws. Remove the 4 screws. 3. Remove the rear entertainment module (RETM). - Pull down on the sides of the RETM to disengage the clips from the bracket. - Disconnect the electrical connector. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation Garage Door Opener Transmitter: Description and Operation UNIVERSAL TRANSMITTER The universal transmitter is an integral part of the LH sun visor and provides a convenient way to substitute up to 3 hand-held transmitters with a single built-in device. The universal transmitter can learn the radio frequency codes of most current transmitters. The universal transmitter: - operates garage doors, gates and home/office lighting and security systems. - learns and transmits the radio frequency of up to 3 hand-held transmitters from any of the systems mentioned above. - is powered by the vehicle battery and charging system. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Garage Door Opener Transmitter: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical damage. VISUAL INSPECTION CHART Mechanical Universal transmitter - Receiver unit 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the cause is not visually evident, verify the symptom and GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7115 Symptom Chart Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7116 Garage Door Opener Transmitter: Pinpoint Tests PINPOINT TEST A: THE UNIVERSAL TRANSMITTER IS INOPERATIVE Normal Operation The universal transmitter is integral to the LH sun visor assembly. The universal transmitter can be programmed to operate up to 3 garage doors, entry gates, security systems, and home or office lighting. Voltage is supplied to the LH sun visor vanity mirror through circuit 705 (LG/OG). Circuit 57 (BK) provides the LH sun visor vanity mirror ground. This pinpoint test is intended to diagnose the following: - Universal transmitter - Receiver unit A1 A2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7117 Garage Door Opener Transmitter: Programming and Relearning UNIVERSAL TRANSMITTER PROGRAMMING NOTE: A new battery in the hand-held transmitter may allow quicker and easier training due to a more accurate transmission of the radio frequency signal. 1. Verify the hand-held transmitter is operative. 2. Turn the key to the ON position. 3. Prepare for programming the universal transmitter by erasing all 3 channels by holding down the 2 outside buttons until the red light begins to flash (20-30 seconds). Release both buttons. 4. Select 1 of the 3 universal transmitter buttons to be used for programming. 5. Hold the end of the hand-held transmitter 25-76 mm (1-3 in) away from the front surface of the universal transmitter so that the universal transmitter red light can still be seen. 6. NOTE: During programming, the hand-held transmitter may automatically stop transmitting after 2 seconds, which may not be long enough to program the universal transmitter. If programming with this type of hand-held transmitter, continue to hold the button on the universal transmitter while pressing and releasing the hand-held transmitter button every 2 seconds. At the same time, press the hand-held transmitter button and the desired button on the universal transmitter until the red light on the universal transmitter flashes first slowly, and then rapidly. Release both buttons when the rapid flashing begins. 7. Firmly press and hold for 5 seconds, then release the just-trained universal transmitter button up to 2 separate times to activate the door. If after 2 separate times, the door still does not activate, press and hold the just-trained universal transmitter button and observe the indicator light. If the indicator light stays on constantly, programming is complete and the device should activate when the universal transmitter button is pressed and released. - If the indicator light blinks rapidly for 2 seconds and then turns to a constant light, follow the Training a Garage Door Opener Equipped With "Rolling Codes" procedure to complete the programming of a rolling code equipped device. Training a Garage Door Opener Equipped With "Rolling Codes" 1. At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. 2. Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) There are 30 seconds to initiate step 3. 3. Return to the vehicle and firmly press, hold for 2 seconds and release the programmed universal transmitter button. Repeat the press/hold/release sequence a second time, and depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming process. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Page 7118 Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System: > 10-2-8 > Feb > 10 > SYNC(R) System Defaults To 'Privacy Mode' Global Positioning System: Customer Interest SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Global Positioning System: All Technical Service Bulletins SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7136 Memory Positioning Module: Diagrams C341A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7137 C341B C314C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7138 C341D Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7139 Memory Positioning Module: Service and Repair DRIVER SEAT MODULE (DSM) Removal and Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new driver seat module (DSM) after installation. 1. Remove the driver seat. 2. Remove the 2 screws. - To install, tighten to 7 Nm (62 lb-in). 3. Disconnect the 4 electrical connectors and remove the DSM. 4. NOTE: Once the module is installed it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 7143 C3246 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest for Navigation System: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Navigation System: Customer Interest SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Navigation System: All Technical Service Bulletins SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions Navigation System: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7159 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7160 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7161 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7162 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7163 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7164 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7165 Navigation System: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7166 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7167 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7168 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7169 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7170 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7171 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7172 Navigation System: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 130-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7173 130-2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7174 130-3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7175 130-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7176 130-5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7177 130-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 7178 130-7 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 7183 C2003 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Sensor > Component Information > Diagrams C2090 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 7190 C2235 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams C3020 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 7195 Amplifier: Service and Repair SUBWOOFER AMPLIFIER Removal and Installation 1. Remove the speaker enclosure. 2. Disconnect the subwoofer amplifier electrical connector. 3. Remove the 4 screws and the subwoofer amplifier. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Locations View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Locations > Page 7199 C2358 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Service and Repair > Procedures Radio/Stereo: Procedures Audio Unit Part Number Retrieval AUDIO UNIT PART NUMBER RETRIEVAL Audio Systems Without Navigation NOTE: The terms "audio control module (ACM)" and "audio unit" refer to the same component. 1. Turn the ACM on. 2. Press and hold preset buttons 3 and 6 for 3 seconds. The speaker walk-around test will begin. 3. Before the speaker walk-around test is complete, press preset button 6. 4. NOTE: This step will cause the ACM to auto-scroll through configuration 1, configuration 2, EEPROM number, and ACM part number. Press the TUNE UP button. 5. NOTE: Step 4 may need to be repeated until the ACM part number can be recorded. Record the ACM part number. 6. Turn the ACM off. Navigation Audio System 1. Turn the ACM on. 2. Press and hold preset buttons 3 and 6 for 3 seconds. The speaker walk-around test will begin. 3. Before the speaker walk-around test is complete, press END TEST on the display screen. 4. Select SYSTEM INFO from the menu. 5. Record the ACM part number. 6. Turn the ACM off. Satellite Radio Receiver Electronic Serial Number (ESN) Retrieval SATELLITE RADIO RECEIVER ELECTRONIC SERIAL NUMBER (ESN) RETRIEVAL Audio Systems Without Navigation 1. Operate the audio system in satellite radio mode. 2. Press and hold the AUX button and preset button 1, simultaneously. - The satellite radio receiver electronic serial number (ESN) will be displayed on the screen. 3. Record the satellite radio receiver ESN. 4. Turn the audio system off. Audio Systems With Navigation 1. Turn the audio system on. 2. Press the MENU button. 3. Select the SYSTEM INFO tab. 4. NOTE: The satellite radio receiver ESN is shown on the lower left corner of the screen with the text "SR ESN:". Record the satellite radio receiver ESN. 5. Turn the audio system off. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Service and Repair > Procedures > Page 7202 Radio/Stereo: Removal and Replacement SATELLITE DIGITAL AUDIO RECEIVER SYSTEM (SDARS) MODULE Removal and Installation 1. Remove the audio control module (ACM). 2. Remove the 4 screws and the satellite digital audio receiver system (SDARS) module. - Disconnect the electrical and antenna connectors. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Locations View 151-20 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Locations > Page 7206 Remote Control: Service and Repair STEERING WHEEL CONTROLS Removal and Installation 1. Remove the driver air bag module. 2. Remove the steering wheel audio control switch. - Disconnect the electrical connector. - Remove the 2 nuts. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 09-20-10 > Oct > 09 > Audio System - Inoperative/Speaker Popping Noise Speaker: Customer Interest Audio System - Inoperative/Speaker Popping Noise TSB 09-20-10 10/19/09 SPEAKER POP AND/OR RADIO INOPERATIVE/BLANK/LOCKED UP FORD: 2008-2009 Fusion, Mustang 2008 F-150 2008-2009 Edge, Expedition, Explorer Sport Trac, Explorer, F-Super Duty MERCURY: 2008-2009 Milan, Mountaineer This article supersedes TSB 9-16-3 to update the vehicle lines. ISSUE Some 2008-2009 F-Super Duty, Expedition, Explorer, Explorer Sport Trac, Mountaineer, Fusion, Milan, Mustang,, Edge and 2008 F-150 vehicles equipped with Single CD and CDX6 Audio Control Modules (ACM), may exhibit either a speaker pop noise and/or a condition where the ACM is completely inoperative or will not power on. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The speaker pop typically happens after an extended drive period when vehicle is warm and opening/closing a door; however, it may happen anytime the (ACM) is turned off. Using the vehicle heater through the instrument panel (IP) panel vents (on high setting) may also cause the condition to repeat more often. The ACM may be completely inoperative, blank. or locked up. It may be caused by a software lockup event within the ACM. Reprogram the ACM to the latest calibration using IDS 63.02 and higher. This new calibration is not included in the VCM 2009.9 DVD Calibration files may also be obtained at the website. An ACM replacement will be necessary for 2008 F-150 for the above symptoms, it can not be reprogrammed with IDS. Reference Workshop Manual, Section 415-00 for removal and installation instructions. Please specify speaker pop noise/lock up on the 1878 form when ordering a replacement ACM for F-150. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092010A 2008-2009 F-Super Duty, 0.3 Hr. Expedition, Explorer, Mountaineer, Explorer Sport Trac, Edge, Fusion, Milan, Mustang: Reprogram The ACM (Do Not Use With Any Other Labor Operations) 092010B 2008 F-150: Retrieve The 0.2 Hr. ACM Unit Part Number - Acquire And Order An Exchange Unit Can Be Claimed with Operation C (Do Not Use With Any Labor Operation Outside Of This Article) 092010C 2008 F-150: Replace The 0.4 Hr. ACM, Can Be Claimed Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 09-20-10 > Oct > 09 > Audio System - Inoperative/Speaker Popping Noise > Page 7215 with Operation B (Do Not Use With Any Labor Operation Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 09-20-10 > Oct > 09 > Audio System - Inoperative/Speaker Popping Noise Speaker: All Technical Service Bulletins Audio System - Inoperative/Speaker Popping Noise TSB 09-20-10 10/19/09 SPEAKER POP AND/OR RADIO INOPERATIVE/BLANK/LOCKED UP FORD: 2008-2009 Fusion, Mustang 2008 F-150 2008-2009 Edge, Expedition, Explorer Sport Trac, Explorer, F-Super Duty MERCURY: 2008-2009 Milan, Mountaineer This article supersedes TSB 9-16-3 to update the vehicle lines. ISSUE Some 2008-2009 F-Super Duty, Expedition, Explorer, Explorer Sport Trac, Mountaineer, Fusion, Milan, Mustang,, Edge and 2008 F-150 vehicles equipped with Single CD and CDX6 Audio Control Modules (ACM), may exhibit either a speaker pop noise and/or a condition where the ACM is completely inoperative or will not power on. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The speaker pop typically happens after an extended drive period when vehicle is warm and opening/closing a door; however, it may happen anytime the (ACM) is turned off. Using the vehicle heater through the instrument panel (IP) panel vents (on high setting) may also cause the condition to repeat more often. The ACM may be completely inoperative, blank. or locked up. It may be caused by a software lockup event within the ACM. Reprogram the ACM to the latest calibration using IDS 63.02 and higher. This new calibration is not included in the VCM 2009.9 DVD Calibration files may also be obtained at the website. An ACM replacement will be necessary for 2008 F-150 for the above symptoms, it can not be reprogrammed with IDS. Reference Workshop Manual, Section 415-00 for removal and installation instructions. Please specify speaker pop noise/lock up on the 1878 form when ordering a replacement ACM for F-150. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092010A 2008-2009 F-Super Duty, 0.3 Hr. Expedition, Explorer, Mountaineer, Explorer Sport Trac, Edge, Fusion, Milan, Mustang: Reprogram The ACM (Do Not Use With Any Other Labor Operations) 092010B 2008 F-150: Retrieve The 0.2 Hr. ACM Unit Part Number - Acquire And Order An Exchange Unit Can Be Claimed with Operation C (Do Not Use With Any Labor Operation Outside Of This Article) 092010C 2008 F-150: Replace The 0.4 Hr. ACM, Can Be Claimed Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 09-20-10 > Oct > 09 > Audio System - Inoperative/Speaker Popping Noise > Page 7221 with Operation B (Do Not Use With Any Labor Operation Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker, Left Front C523 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker, Left Front > Page 7224 C612 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker, Left Front > Page 7225 C702 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker, Left Front > Page 7226 C802 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Speaker Walk-Around Test Speaker: Testing and Inspection Speaker Walk-Around Test SPEAKER WALK-AROUND TEST NOTE: To enter the speaker walk-around test, the audio system must be turned on and in radio tuner (AM/FM) mode. 1. To enter the speaker walk-around test, simultaneously press preset buttons 3 and 6. 2. The speaker walk-around test applies sound to each speaker for approximately 1-2 seconds. Each speaker is tested and displayed on the ACM in the following sequence: RF, LF, LR, RR, and SUBWOOFER (if equipped). 3. To exit the speaker walk-around test, turn the key to OFF or turn the audio system off. 4. NOTE: Turning the ignition switch off and back on may not re-enable the rear entertainment module (RETM) buttons. The speaker walk-around test disables the RETM buttons. To re-enable the RETM buttons, turn the audio system off and back on or simultaneously press preset buttons 3 and 5 until the headphone symbol lights up on the ACM display. Simultaneously pressing preset buttons 2 and 4 also re-enables the RETM buttons and changes the system between single play and dual play. In dual play, the rear speakers and subwoofer turn off and the headphone outputs turn on. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Speaker Walk-Around Test > Page 7229 Speaker: Testing and Inspection Audio Control Module (ACM) Self-Diagnostic Test Without Navigation AUDIO CONTROL MODULE (ACM) SELF-DIAGNOSTIC TEST - WITHOUT NAVIGATION NOTE: This self-diagnostic test disables the rear entertainment module (RETM) buttons. Turning the ignition switch off and back on may not re-enable the RETM buttons. To re-enable the RETM buttons, turn the audio system off and back on. The headphone symbol lights up on the ACM display to indicate the RETM buttons are re-enabled. 1. To enter the following tests, press the desired preset button while in the speaker walk-around test or while in the ACM self-diagnostic test. 2. To exit the ACM self-diagnostic test, turn the ignition switch or the audio system off. 3. The self-diagnostic test has 7 manual tests available: - Preset button 1 = Audio internal/external tests. This test verifies the communication to devices internal and external to the audio system. While the tests are carried out, the display flashes SELF TEST. When the tests are completed, the display stops flashing and shows either SELF PASS or SELF FAIL. Failures can be viewed by pressing the tune up button to start the scroll through the list of faults. Each fault is displayed for 2 seconds. After the last fault is displayed, SELF FAIL is returned to the display. Internal/external self-test can be exited anytime by entering another diagnostic test. - Preset button 2 = VIEW/CLEAR DTCS. This test displays and allows the DTCs to be cleared. If no DTCs are found, the display shows NO DTCS. If any DTCs are present, the display shows DTCS FOUND and can be viewed by pressing the tune up button to start scrolling through the list of faults. To clear all DTCs, press the EJECT key. The display shows DTCS CLEAR. - Preset button 3 = SIGNAL STRENGTH TEST. This test displays the average signal strength of the currently tuned frequency. - Preset button 4 = Software version information. This test queries each radio system controller for its software version information. The software levels can be viewed by pressing the tune up button to start scrolling the various microcontrollers. After the last software level is displayed, the SOFT LEVELS message is returned to the display. - Preset button 5 = DISPLAY TEST. This test lights all the display segments for 5 seconds and then turns all segments off. - Preset button 6 = MODULE CONFIGURATION. This tests the ACM configuration. The configuration can be viewed by pressing the tune up button. - CD button = CDX6 diagnostic mode. This test displays the last modes and errors that are saved in the memory. While these tests are being carried out, the ACM displays CD DIAG. The modes and errors can be viewed by pressing the tune up button. 4. To exit the self-diagnostic test, turn the key to OFF or turn the audio system off. 5. If the concern remains and the fault is not detected, GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures With Navigation AUDIO CONTROL MODULE (ACM) SELF-DIAGNOSTIC TEST - WITH NAVIGATION The navigation system provides internal self diagnostics to assist with diagnosing vehicle concerns. Press and hold preset buttons 4 and 6 for 3 seconds. Press the "End Test" button on the screen to exit the speaker walk test. The following diagnostics are available using the on-screen buttons as follows: Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Speaker Walk-Around Test > Page 7230 - ON DEMAND SELF TEST provides internal self-test diagnostics and displays all the DTCs resulting from the self-test. - VIEW DTCs provides a list of all the DTCs currently stored in memory. - CONFIGURATION STATUS displays the current ACM configuration. - SYSTEM INFO provides the ACM part number and software information. - GPS INFO provides satellite information and vehicle current information. - SPEAKER WALK TEST performs a speaker walk-around test. - MULTI-DISC TEST performs a test of the CD player mechanism. - DISPLAY TEST allows the screen colors to be checked and for the individual sectors on the touch screen to be checked. - HARDKEY TEST checks any of the buttons operation. - RADIO SIGNAL STRENGTH performs a test of the antenna signal. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker Speaker: Service and Repair Door Speaker DOOR SPEAKER Front Door Tweeter Speaker Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker > Page 7233 Front Door Speaker Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker > Page 7234 Rear Door Speaker Removal and Installation Front door tweeter 1. Remove the front door trim panel. 2. Remove the 2 screws and the tweeter speaker. Front door 3. Remove the front door speaker trim panel. 4. Remove the 4 screws and the front door speaker. - Disconnect the electrical connector. Rear door 5. Remove the rear door trim panel. 6. Remove the 4 screws and the rear door speaker. - Disconnect the electrical connector. All speakers 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker > Page 7235 Speaker: Service and Repair Speaker Enclosure SPEAKER ENCLOSURE Regular Cab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker > Page 7236 SuperCab and Super Crew Removal and Installation 1. Remove the 3 bolts (Regular Cab) or 4 bolts (SuperCab and Super Crew) and the subwoofer enclosure. - If equipped, remove the 4 bolt caps. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 7242 Accessory Delay Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 7243 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Vehicle Security Module (VSM) - Regular Cab Alarm Module: Service and Repair Vehicle Security Module (VSM) - Regular Cab VEHICLE SECURITY MODULE (VSM) - REGULAR CAB Removal CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage to the module may result. NOTE: - Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new vehicle security module (VSM) after installation. to carry out programmable module installation (PMI). - For the VSM to accept the PMI procedure, the following conditions must be met: a. the headlamp switch must be in the OFF position (must not be in the AUTOLAMP position, if equipped) b. the key must be in the ON position c. the driver door must be open d. the doors must be unlocked electronically by pressing the door lock control switch to the UNLOCK position momentarily Failure to follow this procedure will result in the PMI procedure to fail. - The tire pressure monitoring system (TPMS) functionality is integral to the VSM. - A new VSM is delivered in a "manufacturing mode" with 6 pre-set DTCs. These DTCs require that a successful configuration of the VSM occurs, then a successful TPMS sensor training occurs, then a successful self-test occurs, including the clearing of all DTCs. This is required in order to clear the 6 manufacturing mode DTCs. They are as follows: B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Vehicle Security Module (VSM) - Regular Cab > Page 7248 - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is only necessary if the VSM is being replaced. Upload the module configuration information from the VSM into the scan tool. 2. Turn the key to the OFF position. 3. Remove the LH B-pillar trim panel. 4. Disconnect the 2 VSM electrical connectors. 5. Remove the 2 screws and the VSM. Installation 1. NOTE: If it is necessary to install new VSM mounting screw J-clips, they are available using part number W520822. Position the VSM and install the 2 screws. Tighten to 7 Nm (62 lb-in). 2. Connect the 2 VSM electrical connectors. 3. NOTE: If the VSM is not being replaced, this is the last step that is necessary. Install the LH B-pillar trim panel. 4. NOTE: When successful, this step provides the calibration necessary for the VSM operation and clears DTC B2477. The clearing of the DTC indicates the calibration data has been successfully downloaded to the VSM. Download the VSM configuration information from the scan tool to the VSM. 5. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the VSM has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 6. NOTE: - DTC C2780 will not clear if any other DTCs are present in the VSM. - This step is required to clear DTC C2780, allow the VSM to exit the manufacturing mode, and to make sure there are no other concerns with the newly programmed VSM. Carry out the VSM on-demand self-test by clearing the DTCs and then retrieving the DTCs to confirm all DTCs have been cleared. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Vehicle Security Module (VSM) - Regular Cab > Page 7249 Alarm Module: Service and Repair Vehicle Security Module (VSM) - SuperCab and SuperCrew VEHICLE SECURITY MODULE (VSM) - SUPERCAB AND SUPERCREW Removal CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage to the module may result. NOTE: - Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new vehicle security module (VSM) after installation. to carry out programmable module installation (PMI). - For the VSM to accept the PMI procedure, the following conditions must be met: a. the headlamp switch must be in the OFF position (must not be in the AUTOLAMP position, if equipped) b. the key must be in the ON position c. the driver door must be open d. the doors must be unlocked electronically by pressing the door lock control switch to the UNLOCK position momentarily Failure to follow this procedure will result in the PMI procedure to fail. - The tire pressure monitoring system (TPMS) functionality is integral to the VSM. - A new VSM is delivered in a "manufacturing mode" with 6 pre-set DTCs. These DTCs require that a successful configuration of the VSM occurs, then a successful TPMS sensor training occurs, then a successful self-test occurs, including the clearing of all DTCs. This is required in order to clear the 6 manufacturing mode DTCs. They are as follows: B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Vehicle Security Module (VSM) - Regular Cab > Page 7250 - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is only necessary if the VSM is being replaced. Upload the module configuration information from the VSM into the scan tool. 2. Turn the key to the OFF position. 3. Remove the rear seat backrest. 4. If equipped, remove the rear interior trim panel. 5. Disconnect the 2 VSM electrical connectors. 6. Remove the 2 screws and the VSM. Installation 1. Position the VSM and install the 2 screws. - Tighten to 7 Nm (62 lb-in). 2. Connect the 2 VSM electrical connectors. 3. If equipped, install the rear interior trim panel. 4. NOTE: If the VSM is not being replaced, this is the last step that is necessary. Install the rear seat backrest. 5. NOTE: When successful, this step provides the calibration necessary for the VSM operation and clears DTC B2477. The clearing of the DTC indicates the calibration data has been successfully downloaded to the VSM. Download the VSM configuration information from the scan tool to the VSM. 6. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the VSM has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 7. NOTE: - DTC C2780 will not clear if any other DTCs are present in the VSM. - This step is required to clear DTC C2780, allow the VSM to exit the manufacturing mode, and to make sure there are no other concerns with the newly programmed VSM. Carry out the VSM on-demand self-test by clearing the DTCs and then retrieving the DTCs to confirm all DTCs have been cleared. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: Customer Interest SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: All Technical Service Bulletins SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 7264 Communications Control Module: Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 7265 View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 7266 Communications Control Module: Diagrams C290A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 7267 C290B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 7268 C290C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 7269 Communications Control Module: Service and Repair AUDIO CONTROL MODULE (ACM) Removal and Installation NOTE: - If installing a new navigation audio control module (ACM), remove the navigation DVD if possible, before sending the ACM to an authorized audio system repair facility. - It is not necessary to remove the ACM to retrieve the part number. 1. Remove the instrument panel center finish panel. - Disconnect the electrical connectors. 2. Remove the 4 screws and the ACM. - Disconnect the electrical connectors and the antenna cable. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 7273 View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 7274 Keyless Entry Module: Diagrams C3008A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 7275 C3008B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 7279 C2023 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 7280 Parking Assist Control Module: Service and Repair PARKING AID MODULE Removal and Installation 1. If replacing the parking aid speaker only, proceed as follows: - Disconnect the parking aid speaker electrical connector. - Disengage the parking aid speaker retaining clips. - Remove the parking aid speaker. 2. If replacing the parking aid module (PAM), proceed as follows: - Disconnect the electrical connectors. - Remove the PAM nuts. - Remove the PAM. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 7281 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left C4009 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 7288 C4011 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 7289 C4010 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 7290 C4012 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 7291 Parking Assist Distance Sensor: Service and Repair PARKING AID SENSOR Removal 1. Disconnect the parking aid sensor electrical connector. 2. Press the retaining tabs to remove the parking aid sensor. - Remove the parking aid sensor from the rear bumper. Installation 1. To install the parking aid sensor in the rear bumper, insert the sensor in the opening until the retaining tabs lock in position. 2. Connect the parking aid sensor electrical connector. 3. After installing the sensor(s), use the scan tool to verify that the parking aid sensor PIDs read no object present and that the parking aid sensor attenuation PIDs read between 0-16 ms. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Locations > Page 7295 C2035 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Locations > Page 7296 Parking Assist Switch: Service and Repair PARKING AID SWITCH Removal and Installation 1. Remove the instrument panel center finish panel. 2. Press the retaining tabs to remove the parking aid switch. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Diagrams C2090 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 7303 C2235 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Locations View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7312 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7313 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7314 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7315 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7316 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7317 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7318 Trailer Connector: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7319 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7320 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7321 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7322 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7323 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7324 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7325 Trailer Connector: Connector Views C439A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7326 C439B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7327 Trailer Connector: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 95-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7328 95-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair TRAILER HITCH Trailer Hitch Removal and Installation 1. Remove the rear bumper. 2. Remove the 4 upper trailer hitch assembly-to-bumper bolts. - Remove the rear bumper cover(s) to gain access. - To install, tighten to 175 Nm (129 lb-ft). 3. Remove the 2 lower trailer hitch assembly-to-bumper bolts and the trailer hitch assembly. - To install, tighten to 175 Nm (129 lb-ft). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7336 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7337 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7338 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7339 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7340 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7341 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7342 Trailer Lamps: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7343 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7344 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7345 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7346 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7347 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7348 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7349 Trailer Lamps: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 95-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7350 95-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Trailer Lamps: Initial Inspection and Diagnostic Overview Principles of Operation PRINCIPLES OF OPERATION The trailer tow stop/turn lamps receive voltage from the vehicle rear stop/turn lamp circuits. When a rear stop/turn lamp is illuminated, voltage is also routed to the trailer tow connector. The trailer tow parking lamps are supplied voltage by the trailer tow parking lamp relay. When the parking lamps are illuminated, voltage is also routed to the trailer tow parking lamp relay coil. When the trailer tow parking lamp relay is energized, voltage is supplied to the trailer tow connector. The trailer tow reversing lamp relay is supplied voltage from the reversing lamp circuit. When the reversing lamps are illuminated, voltage is supplied to the trailer tow connector. The trailer battery charging system supplies battery voltage to the trailer tow connector when the ignition switch is in the RUN position. If equipped, the vehicle also supplies circuitry to support the installation of an aftermarket trailer brake control module (TBCM) (installed by the customer). The vehicle circuitry only supplies voltage, ground, stoplamp switch input and a controlling circuit to the trailer tow connector. The trailer electric brakes themselves are controlled by the aftermarket TBCM and not the vehicle itself. Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Central junction box (CJB) fuse(s): 10 (20A) (trailer tow parking and reversing lamps) - 13 (10A) (trailer tow battery charge relay coil side) - 36 (10A) (trailer tow RH stop/turn) - 42 (10A) (trailer tow LH stop/turn) - 105 (30A) (trailer tow electric brakes) - 106 (30A) (trailer tow battery charge relay switch side) - Bulb(s) - Relay(s) - Wiring, terminals or connectors - Trailer brake control module (TBCM) - Trailer tow connector - Trailer NOTE: When diagnosing the trailer tow lamps, begin by verifying that the vehicle exterior lighting systems are all operating correctly with the trailer disconnected. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the concern is not visually evident, verify the symptom. GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7353 Symptom Chart Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7354 Trailer Lamps: Pinpoint Tests Test Y: The Trailer Lamps Are Inoperative - All PINPOINT TEST Y: THE TRAILER LAMPS ARE INOPERATIVE - ALL Normal Operation Ground for all the trailer tow lamps is supplied to the trailer tow connector through circuit 206 (WH). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer tow connector - Trailer Y1-Y2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7355 Y2 Continued Test Z: The Trailer Lamps Are Inoperative - Stop/Turn PINPOINT TEST Z: THE TRAILER LAMPS ARE INOPERATIVE - STOP/TURN Normal Operation The trailer tow connector receives voltage for the stop/turn lamps through circuits 52 (YE) (LH stop/turn) and 64 (DG) (RH stop/turn), which are fused protected by CJB fuses 42 (10A) and 36 (10A), respectively. Circuits 52 (YE) (LH stop/turn) and 64 (DG) (RH stop/turn) are spliced within the CJB to circuits 9 (LG/OG) and 5 (OG/LB), respectively. When the vehicle stop/turn lamps are illuminated, voltage is also supplied to the trailer tow connector. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow connector - CJB - Trailer Z1-Z2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7356 Z2-Z3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7357 Z4-Z5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7358 Z6-Z7 Tests AA: The Trailer Lamps Are Inoperative - Parking PINPOINT TEST AA: THE TRAILER LAMPS ARE INOPERATIVE - PARKING Normal Operation When the vehicle parking lamps are on, circuit 14 (BN) supplies voltage to the coil side of the trailer tow parking lamp relay. Ground is supplied to the trailer tow parking lamp relay through the central junction box (CJB). When the trailer tow parking lamp relay is energized, voltage is routed from the CJB fuse 10 (20A) to the trailer tow connector through circuit 962 (BN/WH). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow parking lamp relay - Trailer tow connector - CJB - Trailer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7359 AA1-AA2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7360 AA2-AA5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7361 AA5-AA8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7362 AA8 Continued Tests AB: The Trailer Lamps Are Inoperative - Reversing PINPOINT TEST AB: THE TRAILER LAMPS ARE INOPERATIVE - REVERSING Normal Operation When the vehicle reversing lamps are on, circuit 1043 (DG/YE) supplies voltage to the coil side of the trailer tow reversing lamp relay. Ground is supplied to the trailer tow reversing lamp relay through the CJB. When the trailer tow reversing lamp relay is energized, voltage is routed from the CJB fuse 10 (20A) to the trailer tow connector through circuit 140 (BK/PK). The trailer tow reversing lamp relay is integral to the CJB and not removable. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer tow connector - CJB - Trailer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7363 AB1-AB3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7364 AB3-AB4 Tests AC: The Trailer Lamps Are On Continuously PINPOINT TEST AC: THE TRAILER LAMPS ARE ON CONTINUOUSLY Normal Operation The parking lamps are controlled by the trailer tow parking lamp relay. When the trailer tow parking lamp relay is energized, voltage is routed from the central junction box (CJB) to the trailer tow connector through circuit 962 (BN/WH). The reversing lamps are controlled by the trailer tow reversing lamp relay. When the trailer tow reversing lamp relay is energized, voltage is routed from the central junction box (CJB) to the trailer tow connector through circuit 140 (BK/PK). The trailer tow reversing lamp relay is integral to the CJB and not removable. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer tow parking lamp relay - CJB - Trailer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7365 AC1-AC4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7366 AC4-AC6 Tests AD: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly PINPOINT TEST AD: THE TRAILER BATTERY CHARGING IS INOPERATIVE/DOES NOT OPERATE CORRECTLY Normal Operation The trailer battery charging is accomplished through the use of the trailer tow battery charge relay. The trailer tow battery charge relay is supplied voltage and ground through the central junction box (CJB). The trailer tow battery charge relay is energized when the ignitions switch is in the RUN position. When energized, the trailer tow battery charge relay routes voltage from the CJB fuse 106 (30A) to the trailer tow connector through circuit 49 (OG). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow connector - Trailer tow battery charge relay - CJB - Trailer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7367 AD1-AD2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7368 AD2-AD4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7369 AD4-AD6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7370 AD6-AD8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7371 AD8-AD9 Tests AE: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly PINPOINT TEST AE: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE/DO NOT OPERATE CORRECTLY Normal Operation The trailer brake control module (TBCM) receives battery voltage from the central junction box (CJB) fuse 105 (30A) through circuit 50 (RD). The trailer brake control module is grounded through circuit 57 (BK). When the brake pedal is applied, the trailer brake control module receives voltage input through circuit 511 (LG) and provides output voltage to the trailer tow connector through circuit 43 (DB). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow connector - CJB - TBCM - Trailer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7372 AE1-AE3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7373 AE3-AE5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7374 AE6-AE8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7375 AE9-AE10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Page 7376 Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 7381 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 7382 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 7385 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 7386 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 7387 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 7388 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Reversing Lamp Non-Serviceable Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 7394 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 7395 Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 7396 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 7397 Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Reversing Lamp Non-Serviceable Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7402 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7403 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7404 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7405 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7406 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7407 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7408 Trailer Connector: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7409 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7410 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7411 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7412 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7413 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7414 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7415 Trailer Connector: Connector Views C439A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7416 C439B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7417 Trailer Connector: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 95-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7418 95-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > Specifications Torque Specifications Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > Specifications > Page 7423 Body Control Systems: Description and Operation MODULE CONTROLLED FUNCTIONS The 2 multifunction electronic modules on this vehicle are: - Driver seat module (DSM) - Vehicle security module (VSM) Driver Seat Module (DSM) The DSM permits 2 automatic memory settings that can be recalled using the memory switches or the remote keyless entry (RKE) transmitter for the following systems: Adjustable brake pedal - Driver seat Vehicle Security Module (VSM) The VSM controls the following functions: Autolamps - Perimeter lighting - Power locks - RKE - Tire pressure monitoring system (TPMS) - Warning lamps Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview Body Control Systems: Initial Inspection and Diagnostic Overview Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Central junction box (CJB) fuse(s): 3 (7.5A) - 109 (30A) - Wiring, terminals or connectors - Driver seat module (DSM) 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the data link connector (DLC). 5. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to diagnose no communication with the scan tool. 6. If the scan tool does not communicate with the vehicle: - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus (Module Communications Network) to diagnose no response from the PCM. 7. Carry out the network test. - If the scan tool responds with no communication for one or more modules, refer to Information Bus (Module Communications Network). - If the network test passes, retrieve and record the continuous memory DTCs. 8. Clear the continuous DTCs and carry out the self-test diagnostics for the DSM. 9. If the DTCs retrieved are related to the concern, go to Diagnostic Trouble Code (DTC) Chart. See: Diagnostic Trouble Code Descriptions 10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures/Driver Seat Module (DSM) Principles of Operation PRINCIPLES OF OPERATION The driver seat module (DSM) supports several vehicle subsystems and permits inter-module and scan tool communications. The memory driver seat feature allows the driver to program a personalized seat position that can be recalled using the memory switches. Refer to Seats. The adjustable pedals are also controlled by the DSM. This system permits the adjustment of the brake and accelerator pedals using the adjustable pedal switch. Refer to Brakes and Traction Control. Principles of Operation PRINCIPLES OF OPERATION The vehicle security module (VSM) controls the power door lock system. The module monitors the door lock/unlock switch inputs from the interior door lock switches. When the module receives an unlock/lock command from any door lock control switch, the module activates the door lock actuators. Refer to Locks. The module also controls the following remote lock/unlock features: - Keyless entry keypad - Panic alarm - Remote keyless entry (RKE) transmitter lock/unlock Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7426 Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Central junction box (CJB) fuse(s): 18 (10A) - 107 (30A) - Wiring, terminals or connectors - Vehicle security module (VSM) 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the data link connector (DLC). 5. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to diagnose no communication with the scan tool. 6. If the scan tool does not communicate with the vehicle: - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus (Module Communications Network) to diagnose no response from the PCM. 7. Carry out the network test. - If the scan tool responds with no communication for one or more modules, refer to Information Bus (Module Communications Network). - If the network test passes, retrieve and record the continuous memory DTCs. 8. Clear the continuous DTCs and carry out the self-test diagnostics for the VSM. 9. If the DTCs retrieved are related to the concern, go to Diagnostic Trouble Code (DTC) Chart. See: Diagnostic Trouble Code Descriptions 10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures/Vehicle Security Module (VSM) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7427 Body Control Systems: Diagnostic Trouble Code Descriptions B106A-B1299 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7428 B1309-B1342 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7429 B1342-B1663 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7430 B1664-B1956 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7431 B1962-B2477 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7432 B287A-B2872 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7433 B2900-B2997 / C1145-C1706 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7434 C1707-C2780 / P0512-P0622 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7435 P1260-PXXXX / U0073-U1950 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7436 U2013-U2051 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7437 Body Control Systems: Symptom Related Diagnostic Procedures Symptom Chart Symptom Chart Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > Tools and Equipment > Driver Seat Module (DSM) Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > Tools and Equipment > Driver Seat Module (DSM) > Page 7440 Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Procedures Front Bumper Cover / Fascia: Procedures TAB REPAIR - BUMPER 1. NOTE: Inspect the bumper cover to determine if part can be repaired to an acceptable level of quality of appearance, fit and durability. Will labor and material cost of the repair meet or exceed the cost of a new replacement bumper cover? If the bumper cover is determined to be repairable, proceed to the following steps. NOTE: The following steps are to be used as a guideline. Depending on what brand of adhesives or patch materials are used, procedures may vary slightly. Remove the affected bumper. 2. Clean the broken tab(s) with a plastics wax and grease remover. 3. Hand sand the repair area with 80-grit sandpaper and remove any foreign material with compressed air 4. Apply a plastics adhesion promoter per label directions to the repair area. 5. Measure and cut a patch of fiberglass cloth or equivalent large enough to form the front of the tab, then slope back in a wedge shape approximately 51 mm (2 in) from original tab. 6. Prepare the repair adhesive cloth patch per manufacturer's instructions and apply to the affected area. - Immediately position the plastic repair material patch to form the tab shape. 7. Allow appropriate cure time and shape the repair tab using a small angle sander. Use extreme care to not sand through the exterior surface. 8. Carry out any required paint repair operations to the bumper cover using Ford-approved paint systems. 9. Reassemble and install the bumper cover. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 7447 Front Bumper Cover / Fascia: Removal and Replacement BUMPER COVER - FRONT Removal and Installation All vehicles 1. Remove the headlamps. 2. NOTE: The front bumper cover-to-front bumper bolts must be replaced with new bolts. Remove the front bumper cover-to-front bumper bolts. 3. Remove the hood over-slam bumper bolts. 4. Remove the hood over-slam bumpers. 5. Remove the front bumper cover brace bolts. 6. Remove the front bumper cover braces. 7. Remove the front bumper cover-to-front fender bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 7448 8. Remove the front bumper cover pin-type retainers. Vehicles equipped with wheelhouse lip mouldings 9. Remove the 4 retaining nuts. 10. Remove the fender splash shield pin-type retainers. 11. Remove the 4 fender splash shield screws. 12. Position aside the wheelhouse lip mouldings. - Disconnect the 6 wheelhouse lip moulding clips. 13. Release the retaining clips. All vehicles 14. Remove the bumper cover bolts located at the headlamp openings. 15. Remove the front bumper cover. 16. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair Rear Bumper Cover / Fascia: Service and Repair TAB REPAIR - BUMPER 1. NOTE: Inspect the bumper cover to determine if part can be repaired to an acceptable level of quality of appearance, fit and durability. Will labor and material cost of the repair meet or exceed the cost of a new replacement bumper cover? If the bumper cover is determined to be repairable, proceed to the following steps. NOTE: The following steps are to be used as a guideline. Depending on what brand of adhesives or patch materials are used, procedures may vary slightly. Remove the affected bumper. 2. Clean the broken tab(s) with a plastics wax and grease remover. 3. Hand sand the repair area with 80-grit sandpaper and remove any foreign material with compressed air 4. Apply a plastics adhesion promoter per label directions to the repair area. 5. Measure and cut a patch of fiberglass cloth or equivalent large enough to form the front of the tab, then slope back in a wedge shape approximately 51 mm (2 in) from original tab. 6. Prepare the repair adhesive cloth patch per manufacturer's instructions and apply to the affected area. - Immediately position the plastic repair material patch to form the tab shape. 7. Allow appropriate cure time and shape the repair tab using a small angle sander. Use extreme care to not sand through the exterior surface. 8. Carry out any required paint repair operations to the bumper cover using Ford-approved paint systems. 9. Reassemble and install the bumper cover. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 08-25-5 > Dec > 08 > Body - L/H Cowl Panel Popped Up Cowl Moulding / Trim: Customer Interest Body - L/H Cowl Panel Popped Up TSB 08-25-5 12/22/08 DRIVERS SIDE COWL PANEL POPPED-UP FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 07-24-5 to update the Service Procedure. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT (Excluding Heritage) vehicles may encounter a concern of the windshield cowl panel not being fully seated, popped up or giving the appearance of being warped. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE HEAVY-PRESSURE MAY RESULT IN BREAKING OF THE J-HOOK. 1. Attempt to seat the cowl panel by gently applying pressure, first downward, then rearward to the inboard rear area of the cowl panel, forward of the windshield to determine if it will engage the sheet metal flange below. (Figure 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 08-25-5 > Dec > 08 > Body - L/H Cowl Panel Popped Up > Page 7462 2. Pull test will confirm if the hooks are engaged and that the sheet metal flange has not been bent too far forward. From the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. (Figure 2) 1. Remove the cowl panel(s). Refer to Workshop Manual (WSM), Section 501-02 for removal instructions. 2. Confirm engagement and proper installation of cowl grill. The cowl design makes use of long J-hooks (Figure 2, view A) on the bottom side of the cowl panel to engage a sheet metal flange below the cowl panel sur[ace area. On vehicles built prior to August 2006, you will need to visually confirm that the J-hooks on the right hand (RH) parts are engaged to the sheet metal flange. The left hand (LH) part will need to be removed to observe this. Vehicles built after August 2006 have a raised feature forward of the screw attachment support tower on the RH part (near the center line of the vehicle), which is to ensure that the cowl panel is not built forward and is in the correct position for the J-hooks to engage the sheet metal flange. Check if the LH cowl panel is installed correctly, you can either tug the part forward or outward (towards the fender). Each move should cause the rear of the part or the split joint between the RH and LH cowl grills to pop up if the J-hooks were not engaged. Relying on an audible confirmation of engagement could cause a false-positive assessment of the parts being installed and retaining correctly and should not be used as the final indicator of correct installation. 3. If the RH part does not have the split joint hook engaged to the sheet metal flange it must be set properly before the LH part can be corrected. Remove LH cowl grill and set aside. Loosen screw on RH cowl grill. Push down and rearward over the hook to engage the sheet metal flange. While holding part rearward, re-tighten the screw. 4. If it is found that the LH parts cannot be installed correctly (the rear edge or split joint pops up after panel is shifted), remove the LH cowl panel (driver side) and place it out of the way. The flange to which the J-hook engages needs to be adjusted slightly upward 3/32" (2 mm) in two areas using a pair of wide bill pliers (Figure 1, view B). Then install the cowl panel and retest by trying to shift either forward or outward. An audible click confirmation of hook engagement could cause a false positive assessment of the parts being installed correctly and should not be used as the final indicator of correct installation. Using the pull test, from the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 08-25-5 > Dec > 08 > Body - L/H Cowl Panel Popped Up > Page 7463 pulled outboard if the hooks are not properly engaged to the flange. This will confirm the flange has not been bent too far forward. If the rear edge and split joint stays down and the margin on the inboard edge to the LH part is consistent, then complete installation of the LH cowl has been achieved. (Figure 3) WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082505A 2004-2008 F-150, 0.3 Hr. 2006-2008 Mark LT: Attempt To Seat Cowl Panel, Includes Time To Adjust Flange If Necessary (Do Not Use With 17508A 17526A, 17528A) DEALER CODING CONDITION BASIC PART NO. CODE 7002010 07 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 08-25-5 > Dec > 08 > Body - L/H Cowl Panel Popped Up Cowl Moulding / Trim: All Technical Service Bulletins Body - L/H Cowl Panel Popped Up TSB 08-25-5 12/22/08 DRIVERS SIDE COWL PANEL POPPED-UP FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 07-24-5 to update the Service Procedure. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT (Excluding Heritage) vehicles may encounter a concern of the windshield cowl panel not being fully seated, popped up or giving the appearance of being warped. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE HEAVY-PRESSURE MAY RESULT IN BREAKING OF THE J-HOOK. 1. Attempt to seat the cowl panel by gently applying pressure, first downward, then rearward to the inboard rear area of the cowl panel, forward of the windshield to determine if it will engage the sheet metal flange below. (Figure 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 08-25-5 > Dec > 08 > Body - L/H Cowl Panel Popped Up > Page 7469 2. Pull test will confirm if the hooks are engaged and that the sheet metal flange has not been bent too far forward. From the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. (Figure 2) 1. Remove the cowl panel(s). Refer to Workshop Manual (WSM), Section 501-02 for removal instructions. 2. Confirm engagement and proper installation of cowl grill. The cowl design makes use of long J-hooks (Figure 2, view A) on the bottom side of the cowl panel to engage a sheet metal flange below the cowl panel sur[ace area. On vehicles built prior to August 2006, you will need to visually confirm that the J-hooks on the right hand (RH) parts are engaged to the sheet metal flange. The left hand (LH) part will need to be removed to observe this. Vehicles built after August 2006 have a raised feature forward of the screw attachment support tower on the RH part (near the center line of the vehicle), which is to ensure that the cowl panel is not built forward and is in the correct position for the J-hooks to engage the sheet metal flange. Check if the LH cowl panel is installed correctly, you can either tug the part forward or outward (towards the fender). Each move should cause the rear of the part or the split joint between the RH and LH cowl grills to pop up if the J-hooks were not engaged. Relying on an audible confirmation of engagement could cause a false-positive assessment of the parts being installed and retaining correctly and should not be used as the final indicator of correct installation. 3. If the RH part does not have the split joint hook engaged to the sheet metal flange it must be set properly before the LH part can be corrected. Remove LH cowl grill and set aside. Loosen screw on RH cowl grill. Push down and rearward over the hook to engage the sheet metal flange. While holding part rearward, re-tighten the screw. 4. If it is found that the LH parts cannot be installed correctly (the rear edge or split joint pops up after panel is shifted), remove the LH cowl panel (driver side) and place it out of the way. The flange to which the J-hook engages needs to be adjusted slightly upward 3/32" (2 mm) in two areas using a pair of wide bill pliers (Figure 1, view B). Then install the cowl panel and retest by trying to shift either forward or outward. An audible click confirmation of hook engagement could cause a false positive assessment of the parts being installed correctly and should not be used as the final indicator of correct installation. Using the pull test, from the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 08-25-5 > Dec > 08 > Body - L/H Cowl Panel Popped Up > Page 7470 pulled outboard if the hooks are not properly engaged to the flange. This will confirm the flange has not been bent too far forward. If the rear edge and split joint stays down and the margin on the inboard edge to the LH part is consistent, then complete installation of the LH cowl has been achieved. (Figure 3) WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082505A 2004-2008 F-150, 0.3 Hr. 2006-2008 Mark LT: Attempt To Seat Cowl Panel, Includes Time To Adjust Flange If Necessary (Do Not Use With 17508A 17526A, 17528A) DEALER CODING CONDITION BASIC PART NO. CODE 7002010 07 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 7471 Cowl Moulding / Trim: By Symptom Technical Service Bulletin # 08-25-5 Date: 081222 Body - L/H Cowl Panel Popped Up TSB 08-25-5 12/22/08 DRIVERS SIDE COWL PANEL POPPED-UP FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 07-24-5 to update the Service Procedure. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT (Excluding Heritage) vehicles may encounter a concern of the windshield cowl panel not being fully seated, popped up or giving the appearance of being warped. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE HEAVY-PRESSURE MAY RESULT IN BREAKING OF THE J-HOOK. 1. Attempt to seat the cowl panel by gently applying pressure, first downward, then rearward to the inboard rear area of the cowl panel, forward of the windshield to determine if it will engage the sheet metal flange below. (Figure 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 7472 2. Pull test will confirm if the hooks are engaged and that the sheet metal flange has not been bent too far forward. From the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. (Figure 2) 1. Remove the cowl panel(s). Refer to Workshop Manual (WSM), Section 501-02 for removal instructions. 2. Confirm engagement and proper installation of cowl grill. The cowl design makes use of long J-hooks (Figure 2, view A) on the bottom side of the cowl panel to engage a sheet metal flange below the cowl panel sur[ace area. On vehicles built prior to August 2006, you will need to visually confirm that the J-hooks on the right hand (RH) parts are engaged to the sheet metal flange. The left hand (LH) part will need to be removed to observe this. Vehicles built after August 2006 have a raised feature forward of the screw attachment support tower on the RH part (near the center line of the vehicle), which is to ensure that the cowl panel is not built forward and is in the correct position for the J-hooks to engage the sheet metal flange. Check if the LH cowl panel is installed correctly, you can either tug the part forward or outward (towards the fender). Each move should cause the rear of the part or the split joint between the RH and LH cowl grills to pop up if the J-hooks were not engaged. Relying on an audible confirmation of engagement could cause a false-positive assessment of the parts being installed and retaining correctly and should not be used as the final indicator of correct installation. 3. If the RH part does not have the split joint hook engaged to the sheet metal flange it must be set properly before the LH part can be corrected. Remove LH cowl grill and set aside. Loosen screw on RH cowl grill. Push down and rearward over the hook to engage the sheet metal flange. While holding part rearward, re-tighten the screw. 4. If it is found that the LH parts cannot be installed correctly (the rear edge or split joint pops up after panel is shifted), remove the LH cowl panel (driver side) and place it out of the way. The flange to which the J-hook engages needs to be adjusted slightly upward 3/32" (2 mm) in two areas using a pair of wide bill pliers (Figure 1, view B). Then install the cowl panel and retest by trying to shift either forward or outward. An audible click confirmation of hook engagement could cause a false positive assessment of the parts being installed correctly and should not be used as the final indicator of correct installation. Using the pull test, from the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 7473 pulled outboard if the hooks are not properly engaged to the flange. This will confirm the flange has not been bent too far forward. If the rear edge and split joint stays down and the margin on the inboard edge to the LH part is consistent, then complete installation of the LH cowl has been achieved. (Figure 3) WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082505A 2004-2008 F-150, 0.3 Hr. 2006-2008 Mark LT: Attempt To Seat Cowl Panel, Includes Time To Adjust Flange If Necessary (Do Not Use With 17508A 17526A, 17528A) DEALER CODING CONDITION BASIC PART NO. CODE 7002010 07 Disclaimer Technical Service Bulletin # 08-25-5 Date: 081222 Body - L/H Cowl Panel Popped Up TSB 08-25-5 12/22/08 DRIVERS SIDE COWL PANEL POPPED-UP FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 07-24-5 to update the Service Procedure. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT (Excluding Heritage) vehicles may encounter a concern of the windshield cowl panel not being fully seated, popped up or giving the appearance of being warped. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE HEAVY-PRESSURE MAY RESULT IN BREAKING OF THE J-HOOK. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 7474 1. Attempt to seat the cowl panel by gently applying pressure, first downward, then rearward to the inboard rear area of the cowl panel, forward of the windshield to determine if it will engage the sheet metal flange below. (Figure 1) 2. Pull test will confirm if the hooks are engaged and that the sheet metal flange has not been bent too far forward. From the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. (Figure 2) 1. Remove the cowl panel(s). Refer to Workshop Manual (WSM), Section 501-02 for removal instructions. 2. Confirm engagement and proper installation of cowl grill. The cowl design makes use of long J-hooks (Figure 2, view A) on the bottom side of the cowl panel to engage a sheet metal flange below the cowl panel sur[ace area. On vehicles built prior to August 2006, you will need to visually confirm that the J-hooks on the right hand (RH) parts are engaged to the sheet metal flange. The left hand (LH) part will need to be removed to observe this. Vehicles built after August 2006 have a raised feature forward of the screw attachment support tower on the RH part (near the center line of the vehicle), which is to ensure that the cowl panel is not built forward and is in the correct position for the J-hooks to engage the sheet metal flange. Check if the LH cowl panel is installed correctly, you can either tug the part forward or outward (towards the fender). Each move should cause the rear of the part or the split joint between the RH and LH cowl grills to pop up if the J-hooks were not engaged. Relying on an audible confirmation of engagement could cause a false-positive assessment of the parts being installed and retaining correctly and should not be used as the final indicator of correct installation. 3. If the RH part does not have the split joint hook engaged to the sheet metal flange it must be set properly before the LH part can be corrected. Remove LH cowl grill and set aside. Loosen screw on RH cowl grill. Push down and rearward over the hook to engage the sheet metal flange. While holding part rearward, re-tighten the screw. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 7475 4. If it is found that the LH parts cannot be installed correctly (the rear edge or split joint pops up after panel is shifted), remove the LH cowl panel (driver side) and place it out of the way. The flange to which the J-hook engages needs to be adjusted slightly upward 3/32" (2 mm) in two areas using a pair of wide bill pliers (Figure 1, view B). Then install the cowl panel and retest by trying to shift either forward or outward. An audible click confirmation of hook engagement could cause a false positive assessment of the parts being installed correctly and should not be used as the final indicator of correct installation. Using the pull test, from the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. This will confirm the flange has not been bent too far forward. If the rear edge and split joint stays down and the margin on the inboard edge to the LH part is consistent, then complete installation of the LH cowl has been achieved. (Figure 3) WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082505A 2004-2008 F-150, 0.3 Hr. 2006-2008 Mark LT: Attempt To Seat Cowl Panel, Includes Time To Adjust Flange If Necessary (Do Not Use With 17508A 17526A, 17528A) DEALER CODING CONDITION BASIC PART NO. CODE 7002010 07 Disclaimer Technical Service Bulletin # 08-25-5 Date: 081222 Body - L/H Cowl Panel Popped Up TSB 08-25-5 12/22/08 DRIVERS SIDE COWL PANEL POPPED-UP FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 7476 This article supersedes TSB 07-24-5 to update the Service Procedure. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT (Excluding Heritage) vehicles may encounter a concern of the windshield cowl panel not being fully seated, popped up or giving the appearance of being warped. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE HEAVY-PRESSURE MAY RESULT IN BREAKING OF THE J-HOOK. 1. Attempt to seat the cowl panel by gently applying pressure, first downward, then rearward to the inboard rear area of the cowl panel, forward of the windshield to determine if it will engage the sheet metal flange below. (Figure 1) 2. Pull test will confirm if the hooks are engaged and that the sheet metal flange has not been bent too far forward. From the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. (Figure 2) 1. Remove the cowl panel(s). Refer to Workshop Manual (WSM), Section 501-02 for removal instructions. 2. Confirm engagement and proper installation of cowl grill. The cowl design makes use of long J-hooks (Figure 2, view A) on the bottom side of the cowl panel to engage a sheet metal flange below the cowl panel sur[ace area. On vehicles built prior to August 2006, you will need to visually Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 7477 confirm that the J-hooks on the right hand (RH) parts are engaged to the sheet metal flange. The left hand (LH) part will need to be removed to observe this. Vehicles built after August 2006 have a raised feature forward of the screw attachment support tower on the RH part (near the center line of the vehicle), which is to ensure that the cowl panel is not built forward and is in the correct position for the J-hooks to engage the sheet metal flange. Check if the LH cowl panel is installed correctly, you can either tug the part forward or outward (towards the fender). Each move should cause the rear of the part or the split joint between the RH and LH cowl grills to pop up if the J-hooks were not engaged. Relying on an audible confirmation of engagement could cause a false-positive assessment of the parts being installed and retaining correctly and should not be used as the final indicator of correct installation. 3. If the RH part does not have the split joint hook engaged to the sheet metal flange it must be set properly before the LH part can be corrected. Remove LH cowl grill and set aside. Loosen screw on RH cowl grill. Push down and rearward over the hook to engage the sheet metal flange. While holding part rearward, re-tighten the screw. 4. If it is found that the LH parts cannot be installed correctly (the rear edge or split joint pops up after panel is shifted), remove the LH cowl panel (driver side) and place it out of the way. The flange to which the J-hook engages needs to be adjusted slightly upward 3/32" (2 mm) in two areas using a pair of wide bill pliers (Figure 1, view B). Then install the cowl panel and retest by trying to shift either forward or outward. An audible click confirmation of hook engagement could cause a false positive assessment of the parts being installed correctly and should not be used as the final indicator of correct installation. Using the pull test, from the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. This will confirm the flange has not been bent too far forward. If the rear edge and split joint stays down and the margin on the inboard edge to the LH part is consistent, then complete installation of the LH cowl has been achieved. (Figure 3) WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082505A 2004-2008 F-150, 0.3 Hr. 2006-2008 Mark LT: Attempt To Seat Cowl Panel, Includes Time To Adjust Flange If Necessary (Do Not Use With 17508A 17526A, 17528A) DEALER CODING CONDITION BASIC PART NO. CODE 7002010 07 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair EXTERIOR FRONT DOOR HANDLE Exploded View Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 7485 Part 2 Removal and Installation 1. Remove the front door trim panel. 2. Position the watershield aside. 3. If equipped, release the lock cylinder actuating rod. 4. Open the clip and disconnect the exterior front door handle actuating rod from the front door latch. 5. Remove the 2 exterior front door handle nuts. - To install, tighten to 7 Nm (62 lb-in). 6. If equipped, disconnect the keyless entry keypad electrical connector and disconnect the harness channel from the door. 7. Remove the 2 exterior front door handle nut seals. 8. Remove the 2 bolts and the exterior front door handle. 9. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Door Latch Remote Control - SuperCab Front Door Latch: Service and Repair Door Latch Remote Control - SuperCab DOOR LATCH REMOTE CONTROL - SUPERCAB Exploded View Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Door Latch Remote Control - SuperCab > Page 7490 Part 2 Removal and Installation 1. Remove the rear door trim panel. 2. Position the watershield aside. 3. Remove the 3 upper door latch bolts. - To install, tighten to 12 Nm (106 lb-in). 4. Remove the 3 latch remote control assembly bolts. - To install, tighten to 12 Nm (106 lb-in). 5. Remove the 3 lower door latch bolts. - To install, tighten to 12 Nm (106 lb-in). 6. Release the actuating rod from the rear door interlock. 7. Remove the latch remote control assembly. 8. To install, reverse the removal procedure. - Lubricate the upper and lower rear door latches after installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Door Latch Remote Control - SuperCab > Page 7491 Front Door Latch: Service and Repair Front Door Latch FRONT DOOR LATCH Exploded View Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Door Latch Remote Control - SuperCab > Page 7492 Part 2 Removal and Installation 1. Remove the front door trim panel. 2. Position the watershield aside. 3. If equipped, disconnect the actuating rod from the door lock cylinder. 4. Open the clip and disconnect the exterior front door handle actuating rod from the front door latch. 5. Remove the 3 front door latch bolts. - To install, tighten to 12 Nm (106 lb-in). 6. Release the interior front door handle actuating cable locator. 7. Disconnect the front door latch electrical connectors. 8. Remove the front door latch. 9. To install, reverse the removal procedure. - Lubricate the front door latch after installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter > System Information > Service and Repair Front Door Limiter: Service and Repair DOOR CHECK ARM - FRONT Removal and Installation 1. Remove the cowl side trim panel. 2. Remove the door check arm-to-door bolts. - To install, tighten to 12 Nm (9 lb-ft). 3. Remove the door check arm-to-body nuts. - To install, tighten to 15 Nm (11 lb-ft). 4. Remove the door check arm. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair Front Door Panel: Service and Repair DOOR TRIM PANEL - FRONT Removal and Installation NOTE: LH side shown, RH side similar. 1. Remove the front door speaker. 2. Remove the speaker watershield. 3. Remove the 2 speaker standoffs. 4. If equipped, remove the window regulator handle. 1 Separate the handle cover from the handle. 2 Remove the screw. 3 Remove the window regulator handle. 4 Remove the spacer. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 7499 5. Remove the window control switch. 6. Remove the bolt. 7. Remove the 2 front door lower bolts. 8. Remove the door handle cover plate. 9. Remove the 2 door handle screws. 10. Remove the front door handle. - Guide the door handle through the opening in the trim panel. 11. CAUTION: Do not pull directly outward on the front door trim panel, as damage may occur. Remove the front door trim panel. Lift upward to remove the front door trim panel. 12. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair DOOR GLASS TOP RUN - FRONT Exploded View Removal and Installation 1. Remove the front door trim panel. 2. Remove the front door window glass. 3. Remove the front door glass top run. - Remove the front door glass top run through the top opening of the front door. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair WINDOW REGULATOR AND MOTOR - FRONT DOOR Exploded View Removal and Installation 1. Remove the front door trim panel. 2. Remove the front door watershield. 3. Secure the front door window glass in the full UPWARD position with tape. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Page 7507 4. Remove the front door window glass-to-regulator assembly bolts. - Loosen the glass clamp fasteners through the 2 vertical slots in the inner door panel. - To install, tighten to 9 Nm (80 lb-in). 5. Disconnect the front door window electrical connector. 6. Remove the front door window regulator bolts. - To install, tighten to 11 Nm (8 lb-ft). 7. Remove the front door window regulator and motor. 8. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair WINDOW REGULATOR AND MOTOR - FRONT DOOR Exploded View Removal and Installation 1. Remove the front door trim panel. 2. Remove the front door watershield. 3. Secure the front door window glass in the full UPWARD position with tape. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 7511 4. Remove the front door window glass-to-regulator assembly bolts. - Loosen the glass clamp fasteners through the 2 vertical slots in the inner door panel. - To install, tighten to 9 Nm (80 lb-in). 5. Disconnect the front door window electrical connector. 6. Remove the front door window regulator bolts. - To install, tighten to 11 Nm (8 lb-ft). 7. Remove the front door window regulator and motor. 8. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair EXTERIOR DOOR HANDLE - SUPERCREW Exploded View Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Page 7517 Part 2 Removal and Installation 1. Remove the rear door trim panel. 2. Position the watershield aside. 3. Open the clip and disconnect the exterior rear door handle actuating rod. 4. Remove the 2 exterior rear door handle nuts. - To install, tighten to 7 Nm (62 lb-in). 5. Remove the 2 exterior rear door handle seals. 6. Remove the 2 exterior rear door handle bolts. - To install, tighten to 7 Nm (62 lb-in). 7. Remove the exterior rear door handle. 8. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Latch - Lower Rear Door Latch: Service and Repair Rear Door Latch - Lower REAR DOOR LATCH - LOWER Exploded View Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Latch - Lower > Page 7522 Part 2 Removal and Installation 1. Remove the rear door trim panel. 2. Position the watershield aside. 3. Remove the 2 rear door handle rivets. 4. Position the rear door handle aside. 5. Disconnect the lower rear door latch actuating cable from the rear door handle. 6. Remove the 3 bolts and the lower rear door latch. - To install, tighten to 12 Nm (106 lb-in). 7. To install, reverse the removal procedure. - Lubricate the lower rear door latch after installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Latch - Lower > Page 7523 Rear Door Latch: Service and Repair Rear Door Latch - SuperCrew REAR DOOR LATCH - SUPERCREW Exploded View Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Latch - Lower > Page 7524 Part 2 Removal and Installation 1. Remove the rear door trim panel. 2. Position the watershield aside. 3. Remove the 3 rear door latch bolts. - To install, tighten to 12 Nm (106 lb-in). 4. Open the clip and disconnect the exterior rear door handle actuating rod. 5. Position the rear door latch aside. 6. Disconnect the 2 rear door latch electrical connectors and remove the rear door latch. 7. To install, reverse the removal procedure. - Lubricate the rear door latch after installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Latch - Lower > Page 7525 Rear Door Latch: Service and Repair Rear Door Latch - Upper REAR DOOR LATCH - UPPER Exploded View Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Latch - Lower > Page 7526 Part 2 Removal and Installation 1. Remove the rear door trim panel. 2. Position the watershield aside. 3. Remove the 2 rear door handle rivets. 4. Position the rear door handle aside. 5. Disconnect the upper rear door latch actuating cable from the rear door handle. 6. Remove the 3 bolts and the upper rear door latch. - To install, tighten to 12 Nm (106 lb-in). 7. To install, reverse the removal procedure. - Lubricate the upper rear door latch after installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair Rear Door Limiter: Service and Repair DOOR CHECK ARM - REAR, SUPERCAB AND SUPERCREW Removal and Installation 1. Remove the door trim panel. 2. Remove the door check arm-to-body nuts. - To install, tighten to 15 Nm (11 lb-ft). 3. Remove the door check arm-to-door nuts. - To install, tighten to 15 Nm (11 lb-ft). 4. Remove the door check arm. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Regular Cab Rear Door Panel: Service and Repair Regular Cab DOOR TRIM PANEL - REAR, REGULAR CAB Removal and Installation 1. Remove the rear door trim panel bolt. 2. Remove the rear door trim panel. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Regular Cab > Page 7534 Rear Door Panel: Service and Repair SuperCab DOOR TRIM PANEL - REAR, SUPERCAB Removal and Installation 1. Remove the rear window garnish mouldings. 2. Remove the 3 rear door trim panel screws. 3. Remove the rear window control switch. - Disconnect the rear window control switch electrical connector. 4. Remove the door handle bezel bolt. 5. Remove the rear door handle cover plate 6. Remove the 2 rear door handle bolts. 7. Remove the rear door handle. 8. CAUTION: Do not pull directly outward on the rear door trim panel, as damage may occur. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Regular Cab > Page 7535 Remove the rear door trim panel. Lift upward and remove the rear door trim panel. 9. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Regular Cab > Page 7536 Rear Door Panel: Service and Repair SuperCrew DOOR TRIM PANEL - REAR, SUPERCREW Removal and Installation 1. Remove the rear window garnish moulding. 2. Remove the window control switch panel. - Disconnect the window control switch electrical connector. 3. Remove the rear door handle cover plate. 4. Remove the 2 rear door handle screws. 5. Remove the rear door handle. - Guide the door handle through the opening in the trim panel. 6. Remove the trim panel bolt. 7. Remove the 3 rear door trim panel bolts. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Regular Cab > Page 7537 8. CAUTION: Do not pull directly outward on the rear door trim panel. Damage may occur. Remove the rear door trim panel. Lift upward to remove the rear door trim panel. 9. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear, SuperCab Rear Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Rear, SuperCab DOOR GLASS TOP RUN - REAR, SUPERCAB Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear, SuperCab > Page 7543 SuperCrew Removal and Installation 1. Position the rear door window glass in the full DOWNWARD position. 2. Remove the rear door trim panel. 3. Remove the rear door mounted speaker. 4. Remove the rear door interior moulding. 5. Remove the rear door window glass top run. - Remove the rear door window glass top run through the top opening of the rear door. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear, SuperCab > Page 7544 Rear Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Rear, SuperCrew DOOR GLASS TOP RUN - REAR, SUPERCREW Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear, SuperCab > Page 7545 SuperCrew Removal and Installation 1. Position the rear door window glass in the full DOWNWARD position. 2. Remove the rear door trim panel. 3. Remove the rear door mounted speaker. 4. Remove the rear door interior moulding. 5. Remove the rear door window glass top run. - Remove the rear door window glass top run through the top opening of the rear door. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab Rear Door Window Motor: Service and Repair Window Regulator and Motor - Rear Door, SuperCab WINDOW REGULATOR AND MOTOR - REAR DOOR, SUPERCAB Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 7550 SuperCrew Removal and Installation 1. Remove the rear door trim panel. 2. Remove the rear door mounted speaker. 3. Remove the rear door interior moulding. 4. Remove the rear door watershield. 5. Secure the rear door glass in the full upward position with tape. 6. NOTE: Some vehicles may use rivets instead of rear door window glass-to-regulator assembly bolts. Remove the rear door window glass-to-regulator assembly bolts. To install, tighten to 11 Nm (8 lb-ft). 7. Disconnect the rear door window motor electrical connector. 8. Remove the rear door window regulator assembly bolts. - To install, tighten to 11 Nm (8 lb-ft). 9. Remove the rear door window regulator assembly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 7551 10. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 7552 Rear Door Window Motor: Service and Repair Window Regulator and Motor - Rear Door, SuperCrew WINDOW REGULATOR AND MOTOR - REAR DOOR, SUPERCREW Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 7553 SuperCrew Removal and Installation 1. Remove the rear door trim panel. 2. Remove the rear door mounted speaker. 3. Remove the rear door interior moulding. 4. Remove the rear door watershield. 5. Secure the rear door glass in the full upward position with tape. 6. NOTE: Some vehicles may use rivets instead of rear door window glass-to-regulator assembly bolts. Remove the rear door window glass-to-regulator assembly bolts. To install, tighten to 11 Nm (8 lb-ft). 7. Disconnect the rear door window motor electrical connector. 8. Remove the rear door window regulator assembly bolts. - To install, tighten to 11 Nm (8 lb-ft). 9. Remove the rear door window regulator assembly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 7554 10. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 7555 Rear Door Window Motor: Service and Repair Window Regulator and Motor - Rear WINDOW REGULATOR AND MOTOR - REAR Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 7556 SuperCrew Material Material Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 7557 Removal and Installation 1. Remove the rear window glass. 2. Disconnect the rear window glass motor electrical connector. 3. Remove the rear window glass regulator and motor assembly screws. - To install, tighten to 11 Nm (8 lb-ft). 4. Remove the rear window glass regulator and motor assembly from the vehicle. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 7558 Rear Door Window Motor: Service and Repair Window Regulator Motor - Rear WINDOW REGULATOR MOTOR - REAR Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 7559 SuperCrew Removal 1. Remove the rear trim panel pin-type retainers. 2. Remove the rear trim panel. 3. Remove the rear corner trim. For SuperCab vehicles, remove the B-pillar trim panel. For SuperCrew vehicles, remove the C-pillar trim panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 7560 4. Disconnect the rear window glass motor electrical connector. 5. Remove the 3 rear window glass regulator and motor assembly screws. 6. Carefully remove the 3 bolts attaching the steel bracket to the plastic cable housing. 7. Hold the plastic cable housing and motor together, place a screwdriver between the drum (located in the cable housing) and the motor housing and pry the motor away from the drum, making sure the drum stays inside the plastic cable housing. Installation 1. Align the motor gear splines onto the drum and press the motor into place, making sure there is correct alignment of the attachment bolt holes. - Install the 3 bolts attaching the steel bracket to the plastic cable housing. 2. Install the rear window glass regulator and motor assembly screws. - Tighten to 11 Nm (8 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 7561 3. Connect the rear window glass motor electrical connector. 4. Install the rear corner trim. For SuperCab vehicles, install the B-pillar trim panel. For SuperCrew vehicles, install the C-pillar trim panel. 5. Install the rear trim panel 6. Install the rear trim panel pin-type retainers. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab Rear Door Window Regulator: Service and Repair Window Regulator and Motor - Rear Door, SuperCab WINDOW REGULATOR AND MOTOR - REAR DOOR, SUPERCAB Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 7566 SuperCrew Removal and Installation 1. Remove the rear door trim panel. 2. Remove the rear door mounted speaker. 3. Remove the rear door interior moulding. 4. Remove the rear door watershield. 5. Secure the rear door glass in the full upward position with tape. 6. NOTE: Some vehicles may use rivets instead of rear door window glass-to-regulator assembly bolts. Remove the rear door window glass-to-regulator assembly bolts. To install, tighten to 11 Nm (8 lb-ft). 7. Disconnect the rear door window motor electrical connector. 8. Remove the rear door window regulator assembly bolts. - To install, tighten to 11 Nm (8 lb-ft). 9. Remove the rear door window regulator assembly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 7567 10. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 7568 Rear Door Window Regulator: Service and Repair Window Regulator and Motor - Rear Door, SuperCrew WINDOW REGULATOR AND MOTOR - REAR DOOR, SUPERCREW Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 7569 SuperCrew Removal and Installation 1. Remove the rear door trim panel. 2. Remove the rear door mounted speaker. 3. Remove the rear door interior moulding. 4. Remove the rear door watershield. 5. Secure the rear door glass in the full upward position with tape. 6. NOTE: Some vehicles may use rivets instead of rear door window glass-to-regulator assembly bolts. Remove the rear door window glass-to-regulator assembly bolts. To install, tighten to 11 Nm (8 lb-ft). 7. Disconnect the rear door window motor electrical connector. 8. Remove the rear door window regulator assembly bolts. - To install, tighten to 11 Nm (8 lb-ft). 9. Remove the rear door window regulator assembly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 7570 10. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair Hood Latch: Service and Repair HOOD LATCH Exploded View Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Page 7575 Part 2 Removal and Installation 1. Remove the 7 pin-type retainers and the radiator upper sight shield. 2. NOTE: Mark the location of the hood latch with a permanent type marker. Remove the 2 hood latch bolts and position the hood latch aside. To install, tighten to 12 Nm (106 lb-in). 3. Disconnect the primary hood latch release cable. 4. Disconnect the secondary hood latch release cable. 5. Remove the hood latch. 6. To install, reverse the removal procedure. - When the hood latch is installed, the latch adjustment must be checked to make sure the latch is installed and aligned correctly. - Lubricate the hood latch after installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair > Hood Latch Release Handle - Primary Hood Latch Release: Service and Repair Hood Latch Release Handle - Primary HOOD LATCH RELEASE HANDLE - PRIMARY Exploded View Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair > Hood Latch Release Handle - Primary > Page 7580 Part 2 Removal and Installation 1. Remove the 7 pin-type retainers and the radiator upper sight shield. 2. NOTE: Mark the location of the hood latch with a permanent type marker. Remove the 2 hood latch bolts and position the hood latch aside. To install, tighten to 12 Nm (106 lb-in). 3. Disconnect the primary hood latch release cable. 4. Remove the A-pillar lower trim panel. 5. Remove the primary hood latch release cable screw. - To install, tighten to 9 Nm (80 lb-in). 6. Release the cable locators and remove the primary hood latch release cable. 7. To install, reverse the removal procedure. - When the hood latch is installed, the latch adjustment must be checked to make sure the latch is installed and aligned correctly. - Lubricate the hood latch after installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair > Hood Latch Release Handle - Primary > Page 7581 Hood Latch Release: Service and Repair Hood Latch Release Handle - Secondary HOOD LATCH RELEASE HANDLE - SECONDARY Exploded View Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair > Hood Latch Release Handle - Primary > Page 7582 Part 2 Removal and Installation 1. Remove the 7 pin-type retainers and the radiator upper sight shield. 2. NOTE: Mark the location of the hood latch with a permanent type marker. Remove the 2 hood latch bolts and position the hood latch aside. To install, tighten to 12 Nm (106 lb-in). 3. Disconnect the secondary hood latch release cable. 4. Disconnect the primary hood latch release cable. 5. Remove the secondary hood latch release screw. - To install, tighten to 8 Nm (71 lb-in). 6. Remove the secondary hood latch release. 7. To install, reverse the removal procedure. - When the hood latch is installed, the latch adjustment must be checked to make sure the latch is installed and aligned correctly. - Lubricate the hood latch after installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair TAILGATE LOCK CYLINDER Removal and Installation NOTE: - When a new lock cylinder is installed, the tailgate lock cylinder, door lock cylinders and the ignition lock cylinder should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is to be used, the new key code is attached to a tag. - The individual door lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build a new lock cylinder to the current key code of the vehicle. 1. Remove the tailgate release handle. 2. Remove retaining clip and the tailgate lock cylinder. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 08-25-5 > Dec > 08 > Body - L/H Cowl Panel Popped Up Cowl Moulding / Trim: Customer Interest Body - L/H Cowl Panel Popped Up TSB 08-25-5 12/22/08 DRIVERS SIDE COWL PANEL POPPED-UP FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 07-24-5 to update the Service Procedure. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT (Excluding Heritage) vehicles may encounter a concern of the windshield cowl panel not being fully seated, popped up or giving the appearance of being warped. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE HEAVY-PRESSURE MAY RESULT IN BREAKING OF THE J-HOOK. 1. Attempt to seat the cowl panel by gently applying pressure, first downward, then rearward to the inboard rear area of the cowl panel, forward of the windshield to determine if it will engage the sheet metal flange below. (Figure 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 08-25-5 > Dec > 08 > Body - L/H Cowl Panel Popped Up > Page 7596 2. Pull test will confirm if the hooks are engaged and that the sheet metal flange has not been bent too far forward. From the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. (Figure 2) 1. Remove the cowl panel(s). Refer to Workshop Manual (WSM), Section 501-02 for removal instructions. 2. Confirm engagement and proper installation of cowl grill. The cowl design makes use of long J-hooks (Figure 2, view A) on the bottom side of the cowl panel to engage a sheet metal flange below the cowl panel sur[ace area. On vehicles built prior to August 2006, you will need to visually confirm that the J-hooks on the right hand (RH) parts are engaged to the sheet metal flange. The left hand (LH) part will need to be removed to observe this. Vehicles built after August 2006 have a raised feature forward of the screw attachment support tower on the RH part (near the center line of the vehicle), which is to ensure that the cowl panel is not built forward and is in the correct position for the J-hooks to engage the sheet metal flange. Check if the LH cowl panel is installed correctly, you can either tug the part forward or outward (towards the fender). Each move should cause the rear of the part or the split joint between the RH and LH cowl grills to pop up if the J-hooks were not engaged. Relying on an audible confirmation of engagement could cause a false-positive assessment of the parts being installed and retaining correctly and should not be used as the final indicator of correct installation. 3. If the RH part does not have the split joint hook engaged to the sheet metal flange it must be set properly before the LH part can be corrected. Remove LH cowl grill and set aside. Loosen screw on RH cowl grill. Push down and rearward over the hook to engage the sheet metal flange. While holding part rearward, re-tighten the screw. 4. If it is found that the LH parts cannot be installed correctly (the rear edge or split joint pops up after panel is shifted), remove the LH cowl panel (driver side) and place it out of the way. The flange to which the J-hook engages needs to be adjusted slightly upward 3/32" (2 mm) in two areas using a pair of wide bill pliers (Figure 1, view B). Then install the cowl panel and retest by trying to shift either forward or outward. An audible click confirmation of hook engagement could cause a false positive assessment of the parts being installed correctly and should not be used as the final indicator of correct installation. Using the pull test, from the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 08-25-5 > Dec > 08 > Body - L/H Cowl Panel Popped Up > Page 7597 pulled outboard if the hooks are not properly engaged to the flange. This will confirm the flange has not been bent too far forward. If the rear edge and split joint stays down and the margin on the inboard edge to the LH part is consistent, then complete installation of the LH cowl has been achieved. (Figure 3) WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082505A 2004-2008 F-150, 0.3 Hr. 2006-2008 Mark LT: Attempt To Seat Cowl Panel, Includes Time To Adjust Flange If Necessary (Do Not Use With 17508A 17526A, 17528A) DEALER CODING CONDITION BASIC PART NO. CODE 7002010 07 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 08-25-5 > Dec > 08 > Body - L/H Cowl Panel Popped Up Cowl Moulding / Trim: All Technical Service Bulletins Body - L/H Cowl Panel Popped Up TSB 08-25-5 12/22/08 DRIVERS SIDE COWL PANEL POPPED-UP FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 07-24-5 to update the Service Procedure. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT (Excluding Heritage) vehicles may encounter a concern of the windshield cowl panel not being fully seated, popped up or giving the appearance of being warped. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE HEAVY-PRESSURE MAY RESULT IN BREAKING OF THE J-HOOK. 1. Attempt to seat the cowl panel by gently applying pressure, first downward, then rearward to the inboard rear area of the cowl panel, forward of the windshield to determine if it will engage the sheet metal flange below. (Figure 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 08-25-5 > Dec > 08 > Body - L/H Cowl Panel Popped Up > Page 7603 2. Pull test will confirm if the hooks are engaged and that the sheet metal flange has not been bent too far forward. From the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. (Figure 2) 1. Remove the cowl panel(s). Refer to Workshop Manual (WSM), Section 501-02 for removal instructions. 2. Confirm engagement and proper installation of cowl grill. The cowl design makes use of long J-hooks (Figure 2, view A) on the bottom side of the cowl panel to engage a sheet metal flange below the cowl panel sur[ace area. On vehicles built prior to August 2006, you will need to visually confirm that the J-hooks on the right hand (RH) parts are engaged to the sheet metal flange. The left hand (LH) part will need to be removed to observe this. Vehicles built after August 2006 have a raised feature forward of the screw attachment support tower on the RH part (near the center line of the vehicle), which is to ensure that the cowl panel is not built forward and is in the correct position for the J-hooks to engage the sheet metal flange. Check if the LH cowl panel is installed correctly, you can either tug the part forward or outward (towards the fender). Each move should cause the rear of the part or the split joint between the RH and LH cowl grills to pop up if the J-hooks were not engaged. Relying on an audible confirmation of engagement could cause a false-positive assessment of the parts being installed and retaining correctly and should not be used as the final indicator of correct installation. 3. If the RH part does not have the split joint hook engaged to the sheet metal flange it must be set properly before the LH part can be corrected. Remove LH cowl grill and set aside. Loosen screw on RH cowl grill. Push down and rearward over the hook to engage the sheet metal flange. While holding part rearward, re-tighten the screw. 4. If it is found that the LH parts cannot be installed correctly (the rear edge or split joint pops up after panel is shifted), remove the LH cowl panel (driver side) and place it out of the way. The flange to which the J-hook engages needs to be adjusted slightly upward 3/32" (2 mm) in two areas using a pair of wide bill pliers (Figure 1, view B). Then install the cowl panel and retest by trying to shift either forward or outward. An audible click confirmation of hook engagement could cause a false positive assessment of the parts being installed correctly and should not be used as the final indicator of correct installation. Using the pull test, from the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 08-25-5 > Dec > 08 > Body - L/H Cowl Panel Popped Up > Page 7604 pulled outboard if the hooks are not properly engaged to the flange. This will confirm the flange has not been bent too far forward. If the rear edge and split joint stays down and the margin on the inboard edge to the LH part is consistent, then complete installation of the LH cowl has been achieved. (Figure 3) WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082505A 2004-2008 F-150, 0.3 Hr. 2006-2008 Mark LT: Attempt To Seat Cowl Panel, Includes Time To Adjust Flange If Necessary (Do Not Use With 17508A 17526A, 17528A) DEALER CODING CONDITION BASIC PART NO. CODE 7002010 07 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 7605 Cowl Moulding / Trim: By Symptom Technical Service Bulletin # 08-25-5 Date: 081222 Body - L/H Cowl Panel Popped Up TSB 08-25-5 12/22/08 DRIVERS SIDE COWL PANEL POPPED-UP FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 07-24-5 to update the Service Procedure. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT (Excluding Heritage) vehicles may encounter a concern of the windshield cowl panel not being fully seated, popped up or giving the appearance of being warped. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE HEAVY-PRESSURE MAY RESULT IN BREAKING OF THE J-HOOK. 1. Attempt to seat the cowl panel by gently applying pressure, first downward, then rearward to the inboard rear area of the cowl panel, forward of the windshield to determine if it will engage the sheet metal flange below. (Figure 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 7606 2. Pull test will confirm if the hooks are engaged and that the sheet metal flange has not been bent too far forward. From the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. (Figure 2) 1. Remove the cowl panel(s). Refer to Workshop Manual (WSM), Section 501-02 for removal instructions. 2. Confirm engagement and proper installation of cowl grill. The cowl design makes use of long J-hooks (Figure 2, view A) on the bottom side of the cowl panel to engage a sheet metal flange below the cowl panel sur[ace area. On vehicles built prior to August 2006, you will need to visually confirm that the J-hooks on the right hand (RH) parts are engaged to the sheet metal flange. The left hand (LH) part will need to be removed to observe this. Vehicles built after August 2006 have a raised feature forward of the screw attachment support tower on the RH part (near the center line of the vehicle), which is to ensure that the cowl panel is not built forward and is in the correct position for the J-hooks to engage the sheet metal flange. Check if the LH cowl panel is installed correctly, you can either tug the part forward or outward (towards the fender). Each move should cause the rear of the part or the split joint between the RH and LH cowl grills to pop up if the J-hooks were not engaged. Relying on an audible confirmation of engagement could cause a false-positive assessment of the parts being installed and retaining correctly and should not be used as the final indicator of correct installation. 3. If the RH part does not have the split joint hook engaged to the sheet metal flange it must be set properly before the LH part can be corrected. Remove LH cowl grill and set aside. Loosen screw on RH cowl grill. Push down and rearward over the hook to engage the sheet metal flange. While holding part rearward, re-tighten the screw. 4. If it is found that the LH parts cannot be installed correctly (the rear edge or split joint pops up after panel is shifted), remove the LH cowl panel (driver side) and place it out of the way. The flange to which the J-hook engages needs to be adjusted slightly upward 3/32" (2 mm) in two areas using a pair of wide bill pliers (Figure 1, view B). Then install the cowl panel and retest by trying to shift either forward or outward. An audible click confirmation of hook engagement could cause a false positive assessment of the parts being installed correctly and should not be used as the final indicator of correct installation. Using the pull test, from the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 7607 pulled outboard if the hooks are not properly engaged to the flange. This will confirm the flange has not been bent too far forward. If the rear edge and split joint stays down and the margin on the inboard edge to the LH part is consistent, then complete installation of the LH cowl has been achieved. (Figure 3) WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082505A 2004-2008 F-150, 0.3 Hr. 2006-2008 Mark LT: Attempt To Seat Cowl Panel, Includes Time To Adjust Flange If Necessary (Do Not Use With 17508A 17526A, 17528A) DEALER CODING CONDITION BASIC PART NO. CODE 7002010 07 Disclaimer Technical Service Bulletin # 08-25-5 Date: 081222 Body - L/H Cowl Panel Popped Up TSB 08-25-5 12/22/08 DRIVERS SIDE COWL PANEL POPPED-UP FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 07-24-5 to update the Service Procedure. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT (Excluding Heritage) vehicles may encounter a concern of the windshield cowl panel not being fully seated, popped up or giving the appearance of being warped. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE HEAVY-PRESSURE MAY RESULT IN BREAKING OF THE J-HOOK. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 7608 1. Attempt to seat the cowl panel by gently applying pressure, first downward, then rearward to the inboard rear area of the cowl panel, forward of the windshield to determine if it will engage the sheet metal flange below. (Figure 1) 2. Pull test will confirm if the hooks are engaged and that the sheet metal flange has not been bent too far forward. From the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. (Figure 2) 1. Remove the cowl panel(s). Refer to Workshop Manual (WSM), Section 501-02 for removal instructions. 2. Confirm engagement and proper installation of cowl grill. The cowl design makes use of long J-hooks (Figure 2, view A) on the bottom side of the cowl panel to engage a sheet metal flange below the cowl panel sur[ace area. On vehicles built prior to August 2006, you will need to visually confirm that the J-hooks on the right hand (RH) parts are engaged to the sheet metal flange. The left hand (LH) part will need to be removed to observe this. Vehicles built after August 2006 have a raised feature forward of the screw attachment support tower on the RH part (near the center line of the vehicle), which is to ensure that the cowl panel is not built forward and is in the correct position for the J-hooks to engage the sheet metal flange. Check if the LH cowl panel is installed correctly, you can either tug the part forward or outward (towards the fender). Each move should cause the rear of the part or the split joint between the RH and LH cowl grills to pop up if the J-hooks were not engaged. Relying on an audible confirmation of engagement could cause a false-positive assessment of the parts being installed and retaining correctly and should not be used as the final indicator of correct installation. 3. If the RH part does not have the split joint hook engaged to the sheet metal flange it must be set properly before the LH part can be corrected. Remove LH cowl grill and set aside. Loosen screw on RH cowl grill. Push down and rearward over the hook to engage the sheet metal flange. While holding part rearward, re-tighten the screw. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 7609 4. If it is found that the LH parts cannot be installed correctly (the rear edge or split joint pops up after panel is shifted), remove the LH cowl panel (driver side) and place it out of the way. The flange to which the J-hook engages needs to be adjusted slightly upward 3/32" (2 mm) in two areas using a pair of wide bill pliers (Figure 1, view B). Then install the cowl panel and retest by trying to shift either forward or outward. An audible click confirmation of hook engagement could cause a false positive assessment of the parts being installed correctly and should not be used as the final indicator of correct installation. Using the pull test, from the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. This will confirm the flange has not been bent too far forward. If the rear edge and split joint stays down and the margin on the inboard edge to the LH part is consistent, then complete installation of the LH cowl has been achieved. (Figure 3) WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082505A 2004-2008 F-150, 0.3 Hr. 2006-2008 Mark LT: Attempt To Seat Cowl Panel, Includes Time To Adjust Flange If Necessary (Do Not Use With 17508A 17526A, 17528A) DEALER CODING CONDITION BASIC PART NO. CODE 7002010 07 Disclaimer Technical Service Bulletin # 08-25-5 Date: 081222 Body - L/H Cowl Panel Popped Up TSB 08-25-5 12/22/08 DRIVERS SIDE COWL PANEL POPPED-UP FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 7610 This article supersedes TSB 07-24-5 to update the Service Procedure. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT (Excluding Heritage) vehicles may encounter a concern of the windshield cowl panel not being fully seated, popped up or giving the appearance of being warped. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE HEAVY-PRESSURE MAY RESULT IN BREAKING OF THE J-HOOK. 1. Attempt to seat the cowl panel by gently applying pressure, first downward, then rearward to the inboard rear area of the cowl panel, forward of the windshield to determine if it will engage the sheet metal flange below. (Figure 1) 2. Pull test will confirm if the hooks are engaged and that the sheet metal flange has not been bent too far forward. From the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. (Figure 2) 1. Remove the cowl panel(s). Refer to Workshop Manual (WSM), Section 501-02 for removal instructions. 2. Confirm engagement and proper installation of cowl grill. The cowl design makes use of long J-hooks (Figure 2, view A) on the bottom side of the cowl panel to engage a sheet metal flange below the cowl panel sur[ace area. On vehicles built prior to August 2006, you will need to visually Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 7611 confirm that the J-hooks on the right hand (RH) parts are engaged to the sheet metal flange. The left hand (LH) part will need to be removed to observe this. Vehicles built after August 2006 have a raised feature forward of the screw attachment support tower on the RH part (near the center line of the vehicle), which is to ensure that the cowl panel is not built forward and is in the correct position for the J-hooks to engage the sheet metal flange. Check if the LH cowl panel is installed correctly, you can either tug the part forward or outward (towards the fender). Each move should cause the rear of the part or the split joint between the RH and LH cowl grills to pop up if the J-hooks were not engaged. Relying on an audible confirmation of engagement could cause a false-positive assessment of the parts being installed and retaining correctly and should not be used as the final indicator of correct installation. 3. If the RH part does not have the split joint hook engaged to the sheet metal flange it must be set properly before the LH part can be corrected. Remove LH cowl grill and set aside. Loosen screw on RH cowl grill. Push down and rearward over the hook to engage the sheet metal flange. While holding part rearward, re-tighten the screw. 4. If it is found that the LH parts cannot be installed correctly (the rear edge or split joint pops up after panel is shifted), remove the LH cowl panel (driver side) and place it out of the way. The flange to which the J-hook engages needs to be adjusted slightly upward 3/32" (2 mm) in two areas using a pair of wide bill pliers (Figure 1, view B). Then install the cowl panel and retest by trying to shift either forward or outward. An audible click confirmation of hook engagement could cause a false positive assessment of the parts being installed correctly and should not be used as the final indicator of correct installation. Using the pull test, from the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. This will confirm the flange has not been bent too far forward. If the rear edge and split joint stays down and the margin on the inboard edge to the LH part is consistent, then complete installation of the LH cowl has been achieved. (Figure 3) WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082505A 2004-2008 F-150, 0.3 Hr. 2006-2008 Mark LT: Attempt To Seat Cowl Panel, Includes Time To Adjust Flange If Necessary (Do Not Use With 17508A 17526A, 17528A) DEALER CODING CONDITION BASIC PART NO. CODE 7002010 07 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair FENDER SPLASH SHIELD Exploded View Removal and Installation 1. If equipped, remove the wheelhouse lip moulding. 2. Remove the front bumper cover brace. 3. Remove the fender splash shield screws. 4. Remove the fender splash shield. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration Body / Frame Mount Bushing: Customer Interest Drivetrain - Highway Speed Vibration TSB 07-10-9 05/28/07 VIBRATION FROM THE DRIVELINE AT HIGHWAY SPEEDS FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 06-12-3 to update the vehicle model years. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT vehicles (excluding F-150 Heritage) may exhibit a vibration, felt in the floorpan and/or steering wheel when driven at highway speeds ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 7626 Refer to the Diagnostic Overview (Figure 1). Based on the customer's description of the concern, find the appropriate Operating Condition, Probable Cause and Repair Action. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 7627 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 7628 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 7629 NOTE IT IS CRITICAL TO IDENTIFY SPECIFIC VEHICLE SPEEDS AND OPERATING CONDITIONS WHEN THE VIBRATION OR NIBBLE IS OCCURRING, TO PROPERLY DIAGNOSE AND REPAIR THE ISSUE. TIRE AND DRIVELINE VIBRATION CAN FEEL SIMILAR. USE OF AN ELECTRONIC VIBRATION ANALYZER (EVA) OR VETRONIX VIBRATION ANALYZER IS RECOMMENDED TO CORRECTLY IDENTIFY VIBRATION SOURCES (ORDERS) AND FREQUENCY (HZ). Parts Block OTHER APPLICABLE ARTICLES: 07-10-08, 06-19-16 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT071009 Claim Labor As Actual Actual Time Or Use SLIS Time Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 4602 42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 07-10-9 > May > 07 > Drivetrain - Highway Speed Vibration > Page 7630 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 07-10-9 > May > 07 > Drivetrain Highway Speed Vibration Body / Frame Mount Bushing: All Technical Service Bulletins Drivetrain - Highway Speed Vibration TSB 07-10-9 05/28/07 VIBRATION FROM THE DRIVELINE AT HIGHWAY SPEEDS FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 06-12-3 to update the vehicle model years. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT vehicles (excluding F-150 Heritage) may exhibit a vibration, felt in the floorpan and/or steering wheel when driven at highway speeds ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 07-10-9 > May > 07 > Drivetrain Highway Speed Vibration > Page 7636 Refer to the Diagnostic Overview (Figure 1). Based on the customer's description of the concern, find the appropriate Operating Condition, Probable Cause and Repair Action. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 07-10-9 > May > 07 > Drivetrain Highway Speed Vibration > Page 7637 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 07-10-9 > May > 07 > Drivetrain Highway Speed Vibration > Page 7638 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 07-10-9 > May > 07 > Drivetrain Highway Speed Vibration > Page 7639 NOTE IT IS CRITICAL TO IDENTIFY SPECIFIC VEHICLE SPEEDS AND OPERATING CONDITIONS WHEN THE VIBRATION OR NIBBLE IS OCCURRING, TO PROPERLY DIAGNOSE AND REPAIR THE ISSUE. TIRE AND DRIVELINE VIBRATION CAN FEEL SIMILAR. USE OF AN ELECTRONIC VIBRATION ANALYZER (EVA) OR VETRONIX VIBRATION ANALYZER IS RECOMMENDED TO CORRECTLY IDENTIFY VIBRATION SOURCES (ORDERS) AND FREQUENCY (HZ). Parts Block OTHER APPLICABLE ARTICLES: 07-10-08, 06-19-16 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT071009 Claim Labor As Actual Actual Time Or Use SLIS Time Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 4602 42 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 07-10-9 > May > 07 > Drivetrain Highway Speed Vibration > Page 7640 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Page 7641 Body / Frame Mount Bushing: Description and Operation FRAME AND BODY MOUNTING The frame consists of 2 steel channel rails, a front crossmember, transmission support crossmember and a rear crossmember (trailer hitch). The side rails and welded crossmembers are not replaced separately. A front frame rail repair kit (5D058 and 5D059) is available if the front rail is to be repaired. For diagonal or X-frame checking, refer to Specifications / Dimensions. When welding is carried out on a vehicle, refer to Welding / Service Precautions. Magnesium Alloy Radiator Support The radiator support is a magnesium die casting with steel bridging brackets bolted to the casting. It replaces the traditional welded-on steel design. The radiator support assembly is welded into the inner fenders and shotgun, via the bridging brackets, just as the traditional weld-on steel radiator supports do. Aluminum spacers between the magnesium radiator support and steel components are required to prevent galvanic corrosion. Minor straightening can be done to the casting as long as no cracking occurs during straightening. Care should be taken to avoid overheating and creating a fire when using oxyacetylene equipment or plasma arc cutting equipment around this or any other magnesium part, for example to remove severely damaged parts. A magnesium casting is extremely unlikely to catch fire, due to its ability to dissipate heat quickly and high temperature necessary to affect the casting. However, if the entire mass of the casting reaches the melting point of magnesium of approximately 427°C (800°F), there is the potential for a fire. Normally, localized heat applied to magnesium casting will simply burn a hole through the casting with no fire risk. In the unlikely event that the entire mass of a magnesium casting does reach 427°C (800°F) and results in a fire, a class D fire extinguisher should be used. Class A, B or C fire extinguishers can spread the burning material without extinguishing it. Water will cause the fire to burn faster. Body Support Mounts The body support mounts: - secure the body to the frame. - cannot reuse body support mounting fasteners. New fasteners must be installed for each fastener that has been removed or loosened. - cannot be lubricated during body support mount installation. - on SuperCrew and SuperCab, share a common fastener with the rear seat. Do not drive the vehicle with the rear seat removed unless the rear seat fasteners are installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Page 7642 Body Support - Front End Sheet Metal (FESM) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Page 7643 Body Support - No. 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Page 7644 Body Support - No. 2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Page 7645 Body Support - No. 3 (LH, All Cabs) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Page 7646 Body Support - No. 3 (RH, All Cabs) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair Cross-Member: Service and Repair TRANSMISSION SUPPORT CROSSMEMBER Transmission Support Crossmember Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 2 exhaust hanger bolts. - To install, tighten to 40 Nm (30 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Page 7650 3. Remove the 2 heat shield screws. - To install, tighten to 20 Nm (15 lb-ft). 4. Support the transmission with a suitable jack. 5. Remove the 2 transmission support nuts. - To install, tighten to 103 Nm (76 lb-ft). 6. Remove the 4 transmission support crossmember bolts. - To install, tighten to 115 Nm (85 lb-ft). 7. Remove the transmission support crossmember. 8. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair TRAILER HITCH Trailer Hitch Removal and Installation 1. Remove the rear bumper. 2. Remove the 4 upper trailer hitch assembly-to-bumper bolts. - Remove the rear bumper cover(s) to gain access. - To install, tighten to 175 Nm (129 lb-ft). 3. Remove the 2 lower trailer hitch assembly-to-bumper bolts and the trailer hitch assembly. - To install, tighten to 175 Nm (129 lb-ft). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 7659 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 7660 Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 7661 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 7662 Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Reversing Lamp Non-Serviceable Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console - Floor Console: Service and Repair Console - Floor CONSOLE - FLOOR Removal and Installation 1. Remove the 3 floor trim panel pushpins. 2. Remove the 2 floor trim panels. 3. Remove the shifter trim panel. 4. Disconnect the shifter cable. 5. Disconnect the floor console electrical connector. 6. Remove the 4 floor console bolts. - To install, tighten to 6 Nm (53 lb-in). 7. Remove the floor console. 8. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console - Floor > Page 7668 Console: Service and Repair Console - Overhead CONSOLE - OVERHEAD Removal and Installation NOTE: If removing the track assembly, remove the headliner. 1. Depress the side tabs and remove the overhead storage bin. 2. Remove the overhead console. 3. Disconnect the 2 overhead console electrical connectors. 4. Remove the dome lamp assembly. 5. Disconnect the dome lamp electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console - Floor > Page 7669 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) Depowering Procedure WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, remove the trim panel, the cover and the RCM fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install the RCM fuse 19 (10A) to the CJB and install the cover and trim panel. 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7675 4. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7676 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, remove the trim panel, the cover, and the RCM fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Remove the driver air bag module. 8. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7677 9. While pushing in on the 2 glove compartment door tabs, position the glove compartment downward. 10. Through the glove compartment opening, release the tabs and disconnect the LH passenger air bag module electrical connector. 11. Attach the restraint system diagnostic tool to the vehicle harness side of the LH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7678 12. Through the glove compartment opening, release the tabs and disconnect the RH passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the RH passenger air bag module electrical connector. 14. Install the RCM fuse 19 (10A) to the CJB. 15. Connect the battery ground cable. Reactivation 1. Remove the RCM fuse 19 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the RH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7679 4. Through the glove compartment opening, connect the RH passenger air bag module electrical connector. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the LH passenger air bag module electrical connector. 6. Through the glove compartment opening, connect the LH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7680 7. Close the glove compartment. 8. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 9. Turn the ignition switch from OFF to ON. 10. Install the RCM fuse 19 (10A) to the CJB and install the cover and trim panel. 11. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 12. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair HEADLINER Removal and Installation All vehicles 1. If equipped, remove the rear entertainment system. 2. If equipped with a single overhead console, remove the overhead console. If equipped with a modular overhead console, remove the modular components. 3. Remove the A-pillar trim panel. 4. Remove the B-pillar trim panel. 5. If equipped, remove the C-pillar trim panel. 6. Disconnect the rear electrical connector. 7. Remove the LH and RH sun visor retaining screws. 8. Remove the LH and RH sun visor retaining clips 9. Remove the sun visors. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 7684 - If equipped, disconnect the electrical connectors. 10. Disconnect the interior mirror electrical connector. 11. If equipped, remove the roof opening panel trim. 12. Remove the 2 garment hooks. 13. If equipped, remove the 2 headliner pin-type retainers. 14. If equipped, remove the 4 modular overhead console track screws. Regular cab and SuperCab 15. Remove the LH and RH rear door latch cover bolts. 16. Remove the LH and RH rear door latch covers. 17. Remove the headliner. - Slide the headliner forward until it detaches from the roof. SuperCrew 18. Position the headliner aside. 19. Remove the rear window glass. 20. Remove the headliner. - Remove the headliner through the rear window glass opening. All vehicles 21. To install, reverse the removal procedure. - Place the headliner in position by aligning the headliner and rails with the front overhead console bracket. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim Trim Panel: Service and Repair Pillar Trim A-Pillar Trim Panel A-PILLAR TRIM PANEL Exploded View Regular Cab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7689 SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7690 SuperCrew (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7691 SuperCrew (Part 2) Removal and Installation 1. NOTE: The bolt covers are one time use only. Remove the assist handle bolt covers. To remove, start at the handle side of cover and work outward. 2. Remove the assist handle bolts. - To install, tighten to 7 Nm (62 lb-in). 3. Remove the A-pillar trim panel. 4. To install, reverse the removal procedure. B-Pillar Trim Panel - Regular Cab B-PILLAR TRIM PANEL - REGULAR CAB Exploded View Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7692 Regular Cab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7693 SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7694 SuperCrew (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7695 SuperCrew (Part 2) Removal and Installation 1. Remove the front door scuff plate. 2. Remove the pin-type retainers from the rear trim panel. 3. Remove the rear trim panel. 4. Remove the B-pillar bolt cover. 5. Remove the B-pillar bolt. 6. Remove the B-pillar trim panel. 7. To install, reverse the removal procedure. B-Pillar Trim Panel - SuperCab B-PILLAR TRIM PANEL - SUPERCAB Exploded View Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7696 Regular Cab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7697 SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7698 SuperCrew (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7699 SuperCrew (Part 2) Removal and Installation 1. Remove the front door scuff plate. 2. Remove the lower safety belt anchor bolt. - To install, tighten to 48 Nm (35 lb-ft). 3. Remove the B-pillar trim cover. 4. Remove the B-pillar bolt trim cover. 5. Remove the B-pillar bolt. 6. Remove the safety belt bolt cover. 7. Remove the safety belt bolt. - To install, tighten to 48 Nm (35 lb-ft). 8. Remove the rear seat backrest. 9. Remove the pin-type retainer from the B-pillar trim panel. 10. Pull the safety belt through the B-pillar trim panel. 11. Remove the B-pillar trim panel. 12. To install, reverse the removal procedure. B-Pillar Trim Panel - SuperCrew B-PILLAR TRIM PANEL - SUPERCREW Exploded View Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7700 Regular Cab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7701 SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7702 SuperCrew (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7703 SuperCrew (Part 2) Removal and Installation 1. Remove the front door scuff plate. 2. Remove the B-pillar bolt cover. 3. Remove the safety belt trim cover. 4. Remove the B-pillar bolt. 5. Remove the safety belt nut. - To install, tighten to 48 Nm (35 lb-ft). 6. Remove the safety belt anchor bolt. - To install, tighten to 48 Nm (35 lb-ft). 7. Remove the rear door scuff plate. 8. Position the front seat forward. 9. Pull the safety belt through the B-pillar trim panel. 10. Remove the B-pillar trim panel. 11. To install, reverse the removal procedure. C-Pillar Trim Panel C-PILLAR TRIM PANEL Exploded View Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7704 Regular Cab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7705 SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7706 SuperCrew (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7707 SuperCrew (Part 2) Removal and Installation 1. Remove the rear door scuff plate. 2. Remove the safety belt bolt cover. 3. Remove the safety belt bolt. - To install, tighten to 48 Nm (35 lb-ft). 4. Remove the C-pillar bolt trim cover. 5. Remove the C-pillar bolt. 6. Remove the rear seat backrest. 7. Remove the pin-type retainer from the C-pillar trim panel. 8. Remove the lower safety belt bolt cover. 9. Remove the lower safety belt bolt. - To install, tighten to 48 Nm (35 lb-ft). 10. Pull the safety belt through the C-pillar trim panel. 11. Remove the C-pillar trim panel. 12. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7708 Trim Panel: Service and Repair Cowl Side Trim Panel COWL SIDE TRIM PANEL Exploded View Regular Cab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7709 SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7710 SuperCrew (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Pillar Trim > Page 7711 SuperCrew (Part 2) Removal and Installation Both sides 1. Remove the front door scuff plate. LH side 2. Remove the cover plate. RH side 3. Remove the fuse panel access door. 4. Remove the pin-type retainer from the cowl trim panel. Both sides 5. Remove the cowl trim panel. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair DOOR LOCK CYLINDER Removal and Installation NOTE: Individual door lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build a new lock cylinder to the current key code of the vehicle. 1. Remove the exterior front door handle. 2. Remove the retaining clip and the door lock cylinder. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams C500 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Testing and Inspection > Keyless Entry Keypad Code Programming Keyless Entry Key-Pad: Testing and Inspection Keyless Entry Keypad Code Programming KEYLESS ENTRY KEYPAD CODE PROGRAMMING 1. NOTE: The permanent factory keyless entry keypad code cannot be erased. Enter the permanent factory keyless entry keypad code. 2. Press the 1/2 button within 5 seconds to activate the programming mode. Holding the 1/2 button for more than 2 seconds after activation erases the stored customer code. The door locks lock, then unlock, confirming the code is erased. The existing code does not need to be erased to program a new customer code. 3. Within 5 seconds, enter the new 5-digit keyless entry keypad code. The door locks lock and unlock to confirm the new customer code is programmed. 4. To exit the programming mode, wait 5 seconds. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Testing and Inspection > Keyless Entry Keypad Code Programming > Page 7723 Keyless Entry Key-Pad: Testing and Inspection Perimeter Lighting Feature Programming PERIMETER LIGHTING FEATURE PROGRAMMING Programming the Perimeter Lighting Feature Using the Door Lock Control Switch NOTE: The following steps must be carried out within 30 seconds or the procedure will need to be repeated. If the procedure needs to be repeated, wait 30 seconds between programming sessions. 1. Turn the ignition switch from the OFF to the RUN position. 2. Press the unlock button on the door unlock control 3 times. 3. Turn the ignition switch from the RUN to the OFF position. 4. Press the unlock button on the door unlock control switch 3 times. 5. Turn the ignition switch to the RUN position. The horn chirps one time to indicate that programming mode is entered. 6. NOTE: The unlock button must be pressed twice within 5 seconds. Within 30 seconds of entering the programming mode, press the unlock button on the door lock control switch twice to enable/disable the perimeter lighting feature. The horn chirps once if the perimeter lighting is disabled or a chirp followed by a honk if the perimeter lighting is enabled. 7. Programming ends when the ignition switch state changes or times out after 2 minutes. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Testing and Inspection > Page 7724 Keyless Entry Key-Pad: Service and Repair KEYLESS ENTRY KEYPAD Removal and Installation 1. Remove the exterior front door handle. 2. Release the locking tabs and remove the keyless entry keypad. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7728 View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7729 Keyless Entry Module: Diagrams C3008A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7730 C3008B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry Transmitter May Not Operate Keyless Entry Transmitter: Customer Interest Keyless Entry - Transmitter May Not Operate TSB 08-12-9 06/23/08 INOPERATIVE RKE TRANSMITTER (KEY FOB) - DISCHARGED KEY FOB BATTERY FORD: 2008 Crown Victoria, Focus, Mustang 2007-2008 F-150 2008 E-Series, Expedition, Explorer Sport Trac, Explorer, F-Super Duty, Ranger LINCOLN: 2007-2008 Mark LT MERCURY: 2008 Grand Marquis, Mountaineer ISSUE Some 2007-2008 vehicles equipped with a remote keyless entry (RKE) transmitter may exhibit an inoperative Key Fob due to a discharged Key Fob battery. This may be caused by an internal issue with the Key Fob software. This concern only applies to vehicles built within a specific date range with Key Fobs manufactured within a specific date range. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE PERFORMING THIS PROCEDURE WILL HAVE NO EFFECT ON KEY FOB RANGE. REFER TO WORKSHOP MANUAL (WSM), SECTION 501-14 FOR KEY FOB RANGE DIAGNOSTICS. 1. Refer to vehicle list for build date range. (Figure 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry Transmitter May Not Operate > Page 7739 a. If the vehicle was built within the date range, then continue with this procedure. b. If not, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 2. Is the vehicle Key Fob part number 8L3T-15K601-AA (3 button) or 8S4T-15K601-AA (4 button)? (Figure 2) a. Yes - Go to Step 3. b. No - Do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 3. Using a thin coin, open the Key Fob and inspect manufacturer's date code sticker. The first three digits = day of year. The last digit = year. (Figure 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry Transmitter May Not Operate > Page 7740 a. If the first 3 digits are equal to or between 005 and 306 (5th day through 306th day) and the last digit is 7 (year), then proceed to Step 4. b. If the number is outside this specified range, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 4. If the Key Fob is inoperative due to a discharged Key Fob battery, and the date code falls within the specified range, then replace Key Fob. Program the new Key Fob transmitter using the IDS RKE Transmitter Programming Procedure. Reassemble old Key Fob for warranty return analysis. NOTE KEY FOBS REPLACED UNDER WARRANTY WILL BE REQUESTED FOR ANALYSIS AND VERIFICATION OF THE DATE CODE. a. IDS RKE Transmitter Programming Procedure (1) Install known good battery into the suspect Key Fob so that IDS scan tool can identify it. (2) Connect IDS to vehicle. (3) From the Main Toolbox tab: (a) Select - Body. (b) Select - Security. (c) Select - Remote Keyless Entry. (4) Press the "Unlock" button on the suspect Key Fob to view the Transmitter Identification Code (TIC) in IDS. 5. Select "Erase One Key Fob" or the "Erase" button. 6. Select the suspect Key Fob TIC to erase from vehicle memory. 7. Remove battery from suspect Key Fob and reassemble for warranty return. 8. Select "Reprogram a New Keyfob" or the "Program" button. 9. Press the "Unlock" button on the NEW Key Fob. 10. Follow the instructions on the scan tool screen to complete the programming procedure. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081209A 2008 Focus, Mustang, 0.3 Hr. Explorer, Explorer Sport Trac, Mountaineer, E-Series, Expedition, Crown Victoria, Grand Marquis, Ranger, F-Super Duty: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify Date Code Sticker (Do Not Use With 15601A) 081209A 2007-2008 F-150, Mark 0.3 Hr. LT: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify Date Code Sticker (Do Not Use With 15601A) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry Transmitter May Not Operate > Page 7741 DEALER CODING CONDITION BASIC PART NO. CODE 15K601 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter May Not Operate TSB 08-12-9 06/23/08 INOPERATIVE RKE TRANSMITTER (KEY FOB) - DISCHARGED KEY FOB BATTERY FORD: 2008 Crown Victoria, Focus, Mustang 2007-2008 F-150 2008 E-Series, Expedition, Explorer Sport Trac, Explorer, F-Super Duty, Ranger LINCOLN: 2007-2008 Mark LT MERCURY: 2008 Grand Marquis, Mountaineer ISSUE Some 2007-2008 vehicles equipped with a remote keyless entry (RKE) transmitter may exhibit an inoperative Key Fob due to a discharged Key Fob battery. This may be caused by an internal issue with the Key Fob software. This concern only applies to vehicles built within a specific date range with Key Fobs manufactured within a specific date range. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE PERFORMING THIS PROCEDURE WILL HAVE NO EFFECT ON KEY FOB RANGE. REFER TO WORKSHOP MANUAL (WSM), SECTION 501-14 FOR KEY FOB RANGE DIAGNOSTICS. 1. Refer to vehicle list for build date range. (Figure 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 7747 a. If the vehicle was built within the date range, then continue with this procedure. b. If not, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 2. Is the vehicle Key Fob part number 8L3T-15K601-AA (3 button) or 8S4T-15K601-AA (4 button)? (Figure 2) a. Yes - Go to Step 3. b. No - Do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 3. Using a thin coin, open the Key Fob and inspect manufacturer's date code sticker. The first three digits = day of year. The last digit = year. (Figure 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 7748 a. If the first 3 digits are equal to or between 005 and 306 (5th day through 306th day) and the last digit is 7 (year), then proceed to Step 4. b. If the number is outside this specified range, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14. 4. If the Key Fob is inoperative due to a discharged Key Fob battery, and the date code falls within the specified range, then replace Key Fob. Program the new Key Fob transmitter using the IDS RKE Transmitter Programming Procedure. Reassemble old Key Fob for warranty return analysis. NOTE KEY FOBS REPLACED UNDER WARRANTY WILL BE REQUESTED FOR ANALYSIS AND VERIFICATION OF THE DATE CODE. a. IDS RKE Transmitter Programming Procedure (1) Install known good battery into the suspect Key Fob so that IDS scan tool can identify it. (2) Connect IDS to vehicle. (3) From the Main Toolbox tab: (a) Select - Body. (b) Select - Security. (c) Select - Remote Keyless Entry. (4) Press the "Unlock" button on the suspect Key Fob to view the Transmitter Identification Code (TIC) in IDS. 5. Select "Erase One Key Fob" or the "Erase" button. 6. Select the suspect Key Fob TIC to erase from vehicle memory. 7. Remove battery from suspect Key Fob and reassemble for warranty return. 8. Select "Reprogram a New Keyfob" or the "Program" button. 9. Press the "Unlock" button on the NEW Key Fob. 10. Follow the instructions on the scan tool screen to complete the programming procedure. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081209A 2008 Focus, Mustang, 0.3 Hr. Explorer, Explorer Sport Trac, Mountaineer, E-Series, Expedition, Crown Victoria, Grand Marquis, Ranger, F-Super Duty: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify Date Code Sticker (Do Not Use With 15601A) 081209A 2007-2008 F-150, Mark 0.3 Hr. LT: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify Date Code Sticker (Do Not Use With 15601A) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 7749 DEALER CODING CONDITION BASIC PART NO. CODE 15K601 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry Transmitter Programming Keyless Entry Transmitter: Testing and Inspection Remote Keyless Entry Transmitter Programming REMOTE KEYLESS ENTRY TRANSMITTER PROGRAMMING NOTE: - All remote keyless entry (RKE) transmitters must be programmed at the same time. - Programming of the RKE transmitters can be accomplished using a scan tool or by carrying out the following steps: 1. The vehicle must be electronically unlocked before entering program mode using the RKE transmitter, keyless entry keypad (if equipped) or door lock control switch while the driver door is open. 2. Turn the key from OFF to RUN 8 times within 10 seconds, with the eighth turn ending in RUN. If the module successfully enters the program mode, it locks and then unlocks all doors. 3. Within 20 seconds, press any button on an RKE transmitter, and the doors lock and then unlock to confirm that each RKE transmitter is programmed. Repeat this step for each RKE transmitter. 4. If the door locks do not respond for any RKE transmitter, wait several seconds and press the button again. If the door locks still fail to respond, refer to Inspection and Verification. Make sure that no more than the maximum number (4) of RKE transmitters are attempted to be programmed. See: Power Locks/Testing and Inspection/Initial Inspection and Diagnostic Overview/Inspection and Verification 5. Exiting the programming mode is accomplished if one of the following occurs: - The key transitions to the OFF position. Twenty seconds have passed since entering programming mode or since the last RKE transmitter was programmed. - The maximum number (4) of RKE transmitters have been programmed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry Transmitter Programming > Page 7752 Keyless Entry Transmitter: Testing and Inspection Autolock and Horn Chirp Programming AUTOLOCK AND HORN CHIRP PROGRAMMING Using the Keyless Entry Keypad NOTE: - The autolock feature is not available on vehicles equipped with manual transmissions. - A manual enable/disable mode allows the autolock feature to be turned off and on. 1. Enter the 5-digit permanent entry code into the keyless entry keypad. 2. Within 5 seconds of entering the code, press and hold the 7/8 button on the keypad. 3. Within 5 seconds of Step 2, and while holding the 7/8 button, press the 3/4 button on the keypad and release it. 4. NOTE: If the autolock feature is disabled, the horn chirps once. If the autolock feature is enabled, the horn chirps once shortly then sounds a second time for a longer sound of the horn once the above sequence is completed. Within 5 seconds of Step 3, release the 7/8 button on the keypad. Using the Ignition Lock Cylinder NOTE: The autolock feature is not available on vehicles equipped with manual transmissions. 1. Close all the doors. 2. Confirm that the ignition switch is in the OFF position. 3. Turn the ignition switch from OFF to ON. 4. NOTE: Steps 4 through 8 must be carried out within 30 seconds. Press the door lock control switch UNLOCK button 3 times. 5. Turn the ignition switch from ON to OFF. 6. Press the door lock control switch UNLOCK button 3 times. 7. Turn the ignition switch from OFF to ON. 8. Verify that the horn chirps. This indicates the system is in the enable/disable mode and is ready to accept program changes. 9. Press the door lock control switch UNLOCK button one time to toggle the autolock/relock feature OFF. 10. Press the door lock control switch LOCK button once to enter the command. 11. Verify that the horn chirps 1 time. There should only be 1 chirp indicating that autolock/relock feature is disabled. If 1 chirp is heard, followed by a longer sound of the horn, the autolock/relock feature has been enabled. Return to Step 9. 12. Turn the ignition switch to the OFF position to exit the enable/disable mode. 13. Exit the vehicle and verify that the horn chirps once to indicate that a feature has been changed and that autolock/relock is disabled. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Procedures Keyless Entry Transmitter: Procedures Remote Memory Activation REMOTE MEMORY ACTIVATION 1. Position the driver seat and pedals to the desired position. 2. Press the set button on the memory set switch. 3. Within 5 seconds, press the 1 or 2 button on the memory set switch. This stores the configuration for driver 1 or driver 2. 4. Press the set button. 5. Within 5 seconds, press any button on the remote keyless entry (RKE) transmitter and then press the 1 or 2 button on the driver door panel to associate the RKE transmitter with position. 6. If a second memory setting is desired, repeat the procedure with the second RKE transmitter. Remote Memory Deactivation REMOTE MEMORY DEACTIVATION 1. Press the set button on the memory set switch. 2. Within 5 seconds, press any button on the remote keyless entry (RKE) transmitter that you wish to deactivate and then press the set button on the memory set switch. 3. If a second memory setting desired to be deactivated, repeat the procedure with the second RKE transmitter. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Procedures > Page 7755 Keyless Entry Transmitter: Removal and Replacement TAILGATE LATCH REMOTE CONTROL Exploded View Removal and Installation 1. Open and support the tailgate. 2. Remove the 8 screws and the tailgate access panel. - To install, tighten to 5 Nm (44 lb-in). 3. Open the 2 clips and release the 2 tailgate latch actuating rods from the tailgate remote control. 4. Release the 2 tailgate latch actuating rod locators from the tailgate. 5. Remove the 2 nuts and the tailgate remote control. - To install, tighten to 7 Nm (62 lb-in). 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front View 151-31 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front > Page 7761 View 151-30 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front > Page 7762 View 151-33 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Left Front C525 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Left Front > Page 7765 C603 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Left Front > Page 7766 C704 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Left Front > Page 7767 C804 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Lock Actuator Power Door Lock Actuator: Service and Repair Front Door Lock Actuator FRONT DOOR LOCK ACTUATOR Exploded View Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Lock Actuator > Page 7770 Part 2 Removal and Installation 1. Remove the front door latch. 2. Remove the front door lock actuator from the front door latch. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Lock Actuator > Page 7771 Power Door Lock Actuator: Service and Repair Rear Door Lock Actuator REAR DOOR LOCK ACTUATOR Exploded View Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Lock Actuator > Page 7772 Part 2 Removal and Installation 1. Remove the rear door latch. 2. Remove the rear door lock actuator from the rear door latch. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Locations Power Door Lock Control Module: Diagrams Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Locations > Page 7777 View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Locations > Page 7778 Power Door Lock Control Module: Diagrams Vehicle Security Module (VSM) C3008A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Locations > Page 7779 C3008B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side View 151-31 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side > Page 7784 View 151-30 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side C505 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side > Page 7787 C605 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side Power Door Lock Switch: Testing and Inspection Door Lock Switch, Driver Side Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 7790 Power Door Lock Switch: Testing and Inspection Door Lock Switch, Passenger Side Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Page 7791 Power Door Lock Switch: Service and Repair DOOR LOCK CONTROL SWITCH Removal and Installation 1. Remove the switch plate cover. 2. Disconnect the switch plate electrical connectors. 3. Release the door lock control switch tabs on the switch plate and remove the door lock control switch. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair TAILGATE LOCK CYLINDER Removal and Installation NOTE: - When a new lock cylinder is installed, the tailgate lock cylinder, door lock cylinders and the ignition lock cylinder should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is to be used, the new key code is attached to a tag. - The individual door lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build a new lock cylinder to the current key code of the vehicle. 1. Remove the tailgate release handle. 2. Remove retaining clip and the tailgate lock cylinder. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7800 Memory Positioning Module: Diagrams C341A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7801 C341B C314C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7802 C341D Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7803 Memory Positioning Module: Service and Repair DRIVER SEAT MODULE (DSM) Removal and Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new driver seat module (DSM) after installation. 1. Remove the driver seat. 2. Remove the 2 screws. - To install, tighten to 7 Nm (62 lb-in). 3. Disconnect the 4 electrical connectors and remove the DSM. 4. NOTE: Once the module is installed it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 7807 C3246 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Locations View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Locations > Page 7811 C3276 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair Power Mirror Motor: Service and Repair EXTERIOR MIRROR MOTOR Exploded View Aero-Style Mirror Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair > Page 7815 Trailer Tow Mirror Removal and Installation NOTE: The power folding mirrors must be synchronized anytime the mirrors are folded or unfolded without using the exterior mirror control switch, or if a new power folding mirror is installed. Refer to Exterior Mirror Motor Synchronization - Power Folding. See: Testing and Inspection/Programming and Relearning 1. Remove the exterior rear view mirror glass. 2. Remove the 3 exterior rear view mirror motor screws. 3. Disconnect the exterior rear view mirror motor electrical connector. 4. Remove the exterior rear view mirror motor. 5. To install, reverse the removal procedure. - If equipped, synchronize the power folding mirrors. Refer to Exterior Mirror Motor Synchronization - Power Folding. See: Testing and Inspection/Programming and Relearning Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations View 151-30 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7819 C527 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7820 Power Mirror Switch: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7821 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7822 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH Removal and Installation 1. Remove the front door switch panel. - Disconnect the electrical connectors. 2. Remove the exterior mirror control switch. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes Paint: Application and ID Paint Codes VEHICLE CERTIFICATION (VC) CODES Vehicle Certification (VC) Label Locator Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 7828 The VC label contains information on the manufacturer name, the month and year of manufacture, the certification statement and the VIN. This label also includes GVWR information. If a vehicle requires replacement of the VC label and is 4 years old or less, an authorized dealer must submit the VIN to their respective regional office. The regional office will submit a web form to the assembly plant for the replacement label. Once the label has been printed, a representative from the regional office will deliver the label to the dealer and witness installation on the vehicle. If a vehicle is more than 4 years old and requires a replacement label, the dealer must submit a request to the Department of Motor Vehicles. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 7829 Exterior Paint Exterior paint codes may be listed as a 2-part code. The first set of characters identify the primary body color. The second set of characters (if applicable) identify the vehicle accent or 2-tone body color. All colors are base coat/clear coat. Primary Exterior Color Codes CX - Dark Shadow Gray - F-150/Mark LT - DX - Dark Blue Pearl - F-150 - E4 - Vermilion - F-150 - G2 - Redfire - F-150/Mark LT - G3 - Pueblo Gold - F-150/Mark LT - GG - Forest Green - F-150 - HS - Earth Metallic - F-150 - HT - Cinnamon - F-150 - PV - White Chocolate (tri-coat) - F-150/Mark LT - UA - Ebony - F-150/Mark LT - YN - Silver Metallic - F-150/Mark LT - YZ - Oxford White - F-150/Mark LT Exterior Accent Color Codes CX - Dark Shadow Gray - F-150 - G3 - Pueblo Gold - F-150 - HR - Vintage Copper - F-150 - YN - Silver Metallic - F-150 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 7830 Interior Trim Interior trim codes are listed as a 2-part code. The first character identifies the interior trim type. The second character identifies the interior trim color. Interior Trim Type 2 - Tech cloth, 40/20/40 split bench - F-150 - 4 - Milled Pebble perforated leather captains chairs - F-150 - A - Cenery vinyl, 40/20/40 split bench - F-150 - B - Tech cloth 40/20/40 split bench, sport seating - F-150 - C - Speck cloth, 40/20/40 split bench - F-150 - D - Harley Davidson leather captains chairs - F-150 - E - Imola leather, 40/20/40 split bench - F-150 - F - Marta premium cloth captains chairs - F-150 - G - Tech Tu-Tone sport cloth 40/20/40 split bench - F-150 - H - Imola leather captains chairs - F-150 - J - Link Weave sport leather captains chairs - F-150 - K - King Ranch leather captains chairs - F-150 - L - Tech Tu-Tone sport cloth captains chairs - F-150 - M - Marta premium cloth 40/20/40 split bench - F-150 - N - Marta Tu-Tone cloth 40/20/40 split bench - F-150 - P - Marta Tu-Tone cloth captains chairs - F-150 - Q - Link Weave Tu-Tone leather captains chairs - F-150 - R - Tech spot cloth captains chairs - F-150 - S - Speck cloth 40/20/40 split bench - F-150 - T - Cenery vinyl captains chairs - F-150 - U - Speck cloth captains chairs - F-150 - V - Nudo leather captains chairs - Mark LT - X - Tech cloth captains chairs - F-150 - Y - Link Weave leather captains chairs - F-150 (FX2) Interior Trim Color B - Ebony - F-150/Mark LT - E - Medium Flint - F-150 - L - Ebony/Black - Mark LT - W - Medium Pebble Tan - F-150 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 7831 Tape/Paint Stripe Tape and paint stripe codes do not apply. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 7832 Paint: Application and ID Paint Codes Sticker Location VEHICLE CERTIFICATION (VC) CODES Vehicle Certification (VC) Label Locator Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 7833 The VC label contains information on the manufacturer name, the month and year of manufacture, the certification statement and the VIN. This label also includes GVWR information. If a vehicle requires replacement of the VC label and is 4 years old or less, an authorized dealer must submit the VIN to their respective regional office. The regional office will submit a web form to the assembly plant for the replacement label. Once the label has been printed, a representative from the regional office will deliver the label to the dealer and witness installation on the vehicle. If a vehicle is more than 4 years old and requires a replacement label, the dealer must submit a request to the Department of Motor Vehicles. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 7838 View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 7839 Keyless Entry Module: Diagrams C3008A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 7840 C3008B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 7844 Memory Positioning Module: Diagrams C341A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 7845 C341B C314C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 7846 C341D Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 7847 Memory Positioning Module: Service and Repair DRIVER SEAT MODULE (DSM) Removal and Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new driver seat module (DSM) after installation. 1. Remove the driver seat. 2. Remove the 2 screws. - To install, tighten to 7 Nm (62 lb-in). 3. Disconnect the 4 electrical connectors and remove the DSM. 4. NOTE: Once the module is installed it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Locations Power Door Lock Control Module: Diagrams Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Locations > Page 7852 View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Locations > Page 7853 Power Door Lock Control Module: Diagrams Vehicle Security Module (VSM) C3008A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Locations > Page 7854 C3008B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Locations View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Locations > Page 7858 C3276 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Heated Seat Module, Driver Side Front View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Heated Seat Module, Driver Side Front > Page 7863 View 151-29 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Heated Seat Module, Passenger Side Front C329 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Heated Seat Module, Passenger Side Front > Page 7866 C359 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 7867 Seat Heater Control Module: Service and Repair HEATED SEAT MODULE Exploded View Front Seat Backrest - With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 7868 Front Seat Backrest - Without Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 7869 Front Seat Cushion - Driver (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 7870 Front Seat Cushion - Driver (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 7871 Front Seat Cushion - Passenger (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 7872 Front Seat Cushion - Passenger (Part 2) Removal and Installation WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the seat. 2. Disconnect the heated seat module electrical connector. 3. Detach and remove the heated seat module from the seat cushion frame 4. To install, reverse the removal procedure. 5. Install the seat. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations View 151-35 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 7876 C921 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 7882 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 7883 Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 7884 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 7885 Trailer Towing Relay: Testing and Inspection Trailer Tow Relay, Reversing Lamp Non-Serviceable Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair Sunroof / Moonroof Motor: Service and Repair ROOF OPENING PANEL MOTOR Exploded View Removal and Installation NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the roof opening panel, including: whenever the roof opening panel motor has been removed from the roof opening panel assembly, a new roof opening panel motor has been installed or when a new roof opening panel frame has been installed. 1. Remove the headliner. 2. NOTE: Make sure the roof opening panel motor is in the CLOSED position. Disconnect the roof opening panel motor electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Page 7891 3. Remove the 3 roof opening panel motor screws. - To install, tighten to 4 Nm (35 lb-in). 4. Remove the roof opening panel motor. 5. To install, reverse the removal procedure. - Initialize the roof opening panel motor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations View 151-35 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 7895 C912 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 7896 Sunroof / Moonroof Switch: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 7897 Sunroof / Moonroof Switch: Service and Repair ROOF OPENING PANEL CONTROL SWITCH Removal and Installation 1. Remove the overhead console. 2. Disconnect the 2 overhead console electrical connectors. 3. Remove the 4 screws and light assembly from the overhead console. 4. Disengage the clips and remove the switch from the overhead console. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 7898 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Roof Opening Panel Rear Trough Guide Sunroof / Moonroof Track: Service and Repair Roof Opening Panel Rear Trough Guide ROOF OPENING PANEL REAR TROUGH GUIDE Exploded View Removal and Installation NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the roof opening panel, including: whenever the roof opening panel motor has been removed from the roof opening panel assembly, a new roof opening panel motor has been installed or when a new roof opening panel frame has been installed. 1. Remove the trough assembly. 2. Disconnect the trough guide rods from the lifter arm assemblies. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Roof Opening Panel Rear Trough Guide > Page 7903 3. Slide the trough guide back to the slot (approximately 15 mm [0.6 in]) cut in the track. 4. Carefully twist the trough guide through the slot in the track to remove. 5. Inspect the trough guide assembly for damage. If damage is found, inspect the track for broken pieces and remove them. 6. To install, reverse the removal procedure. - Align the roof opening panel. - Initialize the roof opening panel motor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Roof Opening Panel Rear Trough Guide > Page 7904 Sunroof / Moonroof Track: Service and Repair Trough Assembly TROUGH ASSEMBLY Removal and Installation NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the roof opening panel, including: whenever the roof opening panel motor has been removed from the roof opening panel assembly, a new roof opening panel motor has been installed or when a new roof opening panel frame has been installed. 1. Remove the roof opening panel glass. 2. Remove the 2 trough guide retaining screws. 3. Remove the trough from the trough guide assembly. 4. To install, reverse the removal procedure. - Align the roof opening panel. - Initialize the roof opening panel motor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair Sunroof / Moonroof Windguard: Service and Repair AIR DEFLECTOR Exploded View Removal and Installation 1. Place the roof opening panel glass in the fully OPEN position. 2. Remove the 2 air deflector screws. 3. Rotate the front of the air deflector up, and slide the pivot points toward the rear of the vehicle to release the air deflector from the retaining hooks. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair Sunroof / Moonroof Frame: Service and Repair ROOF OPENING PANEL FRAME Exploded View Removal and Installation NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the roof opening panel, including: whenever the roof opening panel motor has been removed from the roof opening panel assembly, a new roof opening panel motor has been installed or when a new roof opening panel frame has been installed. 1. Remove the roof opening panel air deflector. 2. Remove the roof opening panel shield. 3. Remove the headliner. 4. NOTE: Make sure the drain hoses are not kinked during installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Page 7911 Disconnect the 2 roof opening panel front drain hoses from the frame. 5. NOTE: Make sure the drain hoses are not kinked during installation. Disconnect the 2 roof opening panel rear drain hoses from the frame. 6. CAUTION: To avoid damage to the roof opening panel frame, be sure to support the frame when removing the mounting bolts. Remove the 10 roof opening panel frame mounting bolts. To install, tighten to 9 Nm (80 lb-in). 7. Remove the roof opening panel frame. 8. To install, reverse the removal procedure. - Align the roof opening panel. - Initialize the roof opening panel motor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations View 151-35 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 7915 C921 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Glass Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel Glass ROOF OPENING PANEL GLASS Exploded View Removal and Installation NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the roof opening panel, including: whenever the roof opening panel motor has been removed from the roof opening panel assembly, a new roof opening panel motor has been installed or when a new roof opening panel frame has been installed. 1. NOTE: The roof opening panel glass must be in the CLOSED position. Remove the 4 roof opening panel glass screws. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Glass > Page 7920 2. Remove the roof opening panel glass. 3. To install, reverse the removal procedure. - Align the roof opening panel. - Initialize the roof opening panel motor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Glass > Page 7921 Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel Shield ROOF OPENING PANEL SHIELD Exploded View Removal and Installation NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the roof opening panel, including: whenever the roof opening panel motor has been removed from the roof opening panel assembly, a new roof opening panel motor has been installed or when a new roof opening panel frame has been installed. 1. Remove the trough assembly. 2. Slide the roof opening panel shield halfway forward. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Glass > Page 7922 3. Disengage the front roof opening panel shield guide feet. 1 Push the roof opening panel shield toward one side of the vehicle. 2 Carefully flex the front portion of the roof opening panel shield upward to disengage the guide feet. 4. Slide the roof opening panel shield forward and release the rear guide feet. 5. To install, reverse the removal procedure. - Align the roof opening panel. - Initialize the roof opening panel motor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash Sunroof / Moonroof Weatherstrip: Customer Interest Body - Sunroof Water Leaks During High Pressure Car Wash TSB 08-24-8 12/08/08 WATER LEAKS - ROOF OPENING PANEL DURING HIGH PRESSURE CAR WASH FORD: 2005-2008 F-150, F-250, F-350, F-450, F-550 2005-2009 Expedition LINCOLN: 2005-2009 Navigator 2006-2008 Mark LT This article supersedes TSB 08-1-4 to update the Part List and Service procedure. ISSUE Some 2005-2009 Expedition, Navigator, 2005-2008 F-150, F-Super Duty and 2006-2008 Mark LT vehicles with factory installed roof opening panel may experience a water leak at the rear of roof opening panel during a high pressure car wash. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2005-2008 F-150 / F-Super Duty 250-550 / 2006-2008 Mark LT 1. Remove roof opening panel glass only. Refer to Work Shop Manual (WSM), Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. With rear trough removed; wipe clean the top inside of the trough with an alcohol based cleaner or equivalent. 5. Remove the adhesive tape covering from trough seal. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 7931 6. Attach seal to front of trough starting at one end of the trough. Make sure the vertical leg of seal lines up against front flange of trough. (Figures 1-3) 7. Secure seal across entire trough. Apply pressure along entire seal to ensure bonding to trough. 8. Install the rear trough onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 9. Remove protective covering. 10. Install roof opening panel following WSM, Section 501-17. 2005-2009 Expedition / Navigator 1. Remove roof opening panel glass only. Refer to WSM, Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. Install new trough and seal assembly. 5. Install the rear trough and seal assembly onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 6. Remove protective covering. 7. Install roof opening panel following WSM, Section 501-17. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 7932 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082408A 2005-2009 Expedition, 0.5 Hr. Navigator: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) 082408A 2005-2008 F-Super Duty, 0.6 Hr. F-150, 2005-2008 Mark LT: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) DEALER CODING CONDITION BASIC PART NO. CODE 78502C50 07 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Sunroof Water Leaks During High Pressure Car Wash TSB 08-24-8 12/08/08 WATER LEAKS - ROOF OPENING PANEL DURING HIGH PRESSURE CAR WASH FORD: 2005-2008 F-150, F-250, F-350, F-450, F-550 2005-2009 Expedition LINCOLN: 2005-2009 Navigator 2006-2008 Mark LT This article supersedes TSB 08-1-4 to update the Part List and Service procedure. ISSUE Some 2005-2009 Expedition, Navigator, 2005-2008 F-150, F-Super Duty and 2006-2008 Mark LT vehicles with factory installed roof opening panel may experience a water leak at the rear of roof opening panel during a high pressure car wash. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2005-2008 F-150 / F-Super Duty 250-550 / 2006-2008 Mark LT 1. Remove roof opening panel glass only. Refer to Work Shop Manual (WSM), Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. With rear trough removed; wipe clean the top inside of the trough with an alcohol based cleaner or equivalent. 5. Remove the adhesive tape covering from trough seal. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 7938 6. Attach seal to front of trough starting at one end of the trough. Make sure the vertical leg of seal lines up against front flange of trough. (Figures 1-3) 7. Secure seal across entire trough. Apply pressure along entire seal to ensure bonding to trough. 8. Install the rear trough onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 9. Remove protective covering. 10. Install roof opening panel following WSM, Section 501-17. 2005-2009 Expedition / Navigator 1. Remove roof opening panel glass only. Refer to WSM, Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. Install new trough and seal assembly. 5. Install the rear trough and seal assembly onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 6. Remove protective covering. 7. Install roof opening panel following WSM, Section 501-17. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 7939 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082408A 2005-2009 Expedition, 0.5 Hr. Navigator: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) 082408A 2005-2008 F-Super Duty, 0.6 Hr. F-150, 2005-2008 Mark LT: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) DEALER CODING CONDITION BASIC PART NO. CODE 78502C50 07 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Description and Operation Child Seat: Description and Operation ATTACHING SAFETY SEATS WITH TETHER STRAPS Some manufacturers make child safety seats that include a tether strap that goes over the back of the vehicle seat and attaches to an anchoring point. Other manufacturers offer the tether strap as an accessory. Contact the manufacturer of the child safety seat for information about ordering a tether strap. Refer to Child Safety Seat Tether Anchor in the removal and installation portion or the Owner's Literature for usage information. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7948 Memory Positioning Module: Diagrams C341A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7949 C341B C314C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7950 C341D Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7951 Memory Positioning Module: Service and Repair DRIVER SEAT MODULE (DSM) Removal and Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new driver seat module (DSM) after installation. 1. Remove the driver seat. 2. Remove the 2 screws. - To install, tighten to 7 Nm (62 lb-in). 3. Disconnect the 4 electrical connectors and remove the DSM. 4. NOTE: Once the module is installed it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 7955 C3246 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Power Seat Motor Assembly, Left View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Power Seat Motor Assembly, Left > Page 7960 View 151-29 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Power Seat Motor Assembly, Right C3015 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Power Seat Motor Assembly, Right > Page 7963 Power Seat Motor: Diagrams Power Seat Motor Assembly, Left C353 C357 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Sensor View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Sensor > Page 7968 View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Sensor > Page 7969 View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor C372 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 7972 C383 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 7973 C373 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Seat Control Switch, Driver Side Front View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Seat Control Switch, Driver Side Front > Page 7978 View 151-29 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Passenger Side Front C330 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Passenger Side Front > Page 7981 C369 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, Driver Side Front Power Seat Switch: Testing and Inspection Seat Control Switch, Driver Side Front Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, Driver Side Front > Page 7984 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, Driver Side Front > Page 7985 Power Seat Switch: Testing and Inspection Seat Control Switch, Passenger Side Front Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, Driver Side Front > Page 7986 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement Seat Back: Removal and Replacement SEAT BACKREST - FRONT Exploded View Front Seat Backrest - With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7991 Front Seat Backrest - Without Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7992 Front Seat Cushion - Driver (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7993 Front Seat Cushion - Driver (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7994 Front Seat Cushion - Passenger (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7995 Front Seat Cushion - Passenger (Part 2) Special Tool(s) Special Tool(s) Removal and Installation WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Power seat shown, manual seat similar. All seats 1. Remove the seat. 2. If equipped, disconnect the seat control switch electrical connector. 3. NOTE: To aid cushion removal, position the backrest rearward before removing the recliner handle. Remove the recliner handle. Release the clip at the rear of side shield by detaching the clip from the metal bracket on the track. Partially flex the side shield at the rear to Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7996 obtain access to the recliner handle clip. Remove the recliner handle clip (shown removed for clarity) and the recliner handle. 4. If equipped, adjust the lumbar until fully relaxed and remove the lumbar knob. 5. Remove the side shield control panel. 6. If equipped, disconnect the memory SET switch electrical connector. 7. Release the pin-type retainer at the front of the side shield. 8. Remove the 3 screws and side shield. 9. CAUTION: To prevent component damage and avoid setting diagnostic trouble codes (DTCs), the following precautions must be taken: - The position assurance locking wedge must be in the released position when inserting or removing the electrical connector from the safety belt buckle and pretensioner. - Do not install the electrical connector by pushing on the position assurance locking wedge. - Make sure the electrical connector and position assurance locking wedge are fully seated after connecting to the safety belt buckle and pretensioner. Release the locking wedge on the safety belt buckle and pretensioner electrical connector. 10. NOTE: If equipped with manual lumbar, make sure the wire harness is routed above the manual lumbar cable. Disconnect the safety belt buckle and pretensioner electrical connector. 11. Disconnect the safety belt buckle switch electrical connector. 12. If equipped, disconnect the backrest heater mat electrical connector. Seat with seat integrated restraints (SIR) 13. Remove the safety belt anchor nut. - To install, tighten to 55 Nm (41 lb-ft). - If passenger seat, disconnect the belt tension sensor (BTS) electrical connector. All seats 14. If equipped, disconnect the power seat track electrical connector and release any pin-type retainers attached to the seat cushion frame. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7997 15. If equipped, disconnect the 3 memory seat position sensor electrical connectors (one shown) and detach the wiring harness from the cushion frame. 16. Remove the 4 nuts and cushion frame. - To install, tighten to 25 Nm (18 lb-ft). - Disconnect and detach any remaining electrical connectors and wire harness attached to the seat cushion frame. 17. Remove the 2 screws and lumbar adjuster. 18. NOTE: - The lumbar assembly should be fully relaxed before cable disconnection. - Note cable routing for installation. Detach the lumbar cable from the lumbar adjuster and route through the seat. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7998 19. Remove the outboard recliner front bolt and screw. 1 To install, tighten to 35 Nm (26 lb-ft). 2 To install, tighten to 10 Nm (89 lb-in). 20. Remove the inboard recliner front bolt. - To install, tighten to 35 Nm (26 lb-ft). 21. NOTE: Do not damage the plastic pivot bushing when removing or installing the backrest pivot bolt. Remove the inboard backrest pivot bolt. To install, tighten to 35 Nm (26 lb-ft). 22. Remove the outboard backrest pivot bolt and remove the backrest. - To install, tighten to 40 Nm (30 lb-ft). 23. To install, reverse the removal procedure. - Make sure the safety belts and buckles are accessible to the occupants after installation. - Verify the safety belt retractor operates without excessive effort or binding. 24. Install the seat. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 25. WARNING: - Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. - Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. - To prevent system failure, the following precautions must be taken before carrying out the occupant classification sensor (OCS) system reset: Make sure the voltage to the occupant classification system module (OCSM) is above 8.0 volts and less than 18.0 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7999 temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. NOTE: If the first attempt to carry out the OCS system reset is unsuccessful, a second attempt must be made. If the second attempt to carry out the OCS system reset is unsuccessful, a new OCS system service kit must be installed. Carry out the OCS system reset command using the scan tool. 26. Cycle the ignition switch from ON to OFF. 27. NOTE: The ignition switch must be cycled after the OCS system reset. Cycle the ignition switch from OFF to ON. All seats 28. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8000 Seat Back: Overhaul Seat Backrest - Front, Without Seat Integrated Restraints (SIR) SEAT BACKREST - FRONT, WITHOUT SEAT INTEGRATED RESTRAINTS (SIR) Special Tool(s) Special Tool(s) Disassembly and Assembly WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8001 follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - LH shown, RH similar. All seats 1. Remove the seat. 2. Remove the seat backrest. 3. Remove the backrest trim cover. Heated seat 4. Disconnect the backrest heater mat electrical connector. 5. CAUTION: If installing a new backrest foam pad, the heater mat cannot be reused. A new heater mat must be installed. Failure to follow this instruction can result in component or system failure. NOTE: A new heater mat can be attached to a foam pad where an old heater mat was removed but a used heater mat should not be reattached to any foam pad. To service the backrest heater mat, peel and remove the backrest heater mat from the backrest foam pad. If reusing the backrest foam pad, take precautions not to remove excess foam when peeling off the heater mat. If the foam pad is damaged, install a new foam pad and a new heater mat. - For installation, align and lay the heater mat flat on the foam pad surface without any wrinkles and correctly tuck into the valley of the foam pad. All seats 6. Remove the backrest foam pad. 7. Detach the lumbar assembly retainer clips. 8. Remove the lumbar assembly. 9. Remove the recliner roll pin. 10. Remove the recliner strut. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8002 11. Remove the bushing and recliner. 12. To assemble, reverse the disassembly procedure. 13. Install the seat. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 14. WARNING: - Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. - Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. - To prevent system failure, the following precautions must be taken before carrying out the occupant classification sensor (OCS) system reset: Make sure the voltage to the occupant classification system module (OCSM) is above 8.0 volts and less than 18.0 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. NOTE: If the first attempt to carry out the OCS system reset is unsuccessful, a second attempt must made. If the second attempt to carry out the OCS system reset is unsuccessful, a new OCS system service kit must be installed. Carry out the OCS system reset command using the scan tool. 15. Cycle the ignition switch from ON to OFF. 16. NOTE: The ignition switch must be cycled after the OCS system reset. Cycle the ignition switch from OFF to ON. All seats 17. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Seat Backrest - Front, 20 Percent SEAT BACKREST - FRONT, 20 PERCENT Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8003 Front Seat Backrest - 20 Percent, With Storage, SuperCab And SuperCrew (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8004 Front Seat Backrest - 20 Percent, With Storage, SuperCab And SuperCrew (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8005 Front Seat Backrest - 20 Percent, Without Storage (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8006 Front Seat Backrest - 20 Percent, Without Storage (Part 2) Disassembly and Assembly NOTE: Due to locator pin location on the riser frame, 20 percent seat riser frames will not interchange between regular cab vehicles and SuperCab/SuperCrew vehicles. All seats 1. Remove the 20 percent seat. 2. Remove the LH side shield pin-type retainer, screw and shield. 3. Remove the RH upper side shield screw and shield. 4. Remove the RH lower side shield screw and shield. Seats with storage armrest 5. Remove the cupholder assembly screws. - Disconnect the electrical connector and remove the cupholder assembly. All seats 6. Remove the safety belt buckle bolt or safety belt mini-buckle bolt and buckle/mini-buckle on the LH side. - To install, tighten to 55 Nm (41 lb-ft). 7. Remove the safety belt bolt or safety belt buckle bolt and safety belt/buckle on the RH side. - To install, tighten to 55 Nm (41 lb-ft). 8. Remove the LH backrest bracket pivot bolt and pivot bolt bushing. - To install, tighten to 35 Nm (26 lb-ft). Seats with storage armrest 9. Remove the backrest stop bolt. All seats 10. Remove the 2 RH upper adjustable backrest bracket bolts and the adjustable backrest. - To install, tighten to 35 Nm (26 lb-ft). 11. Remove the RH lower adjustable backrest bracket screw, 2 bolts and the adjustable backrest bracket. 12. Remove the LH lower backrest pivot bracket screw, 2 bolts and the backrest pivot bracket. Seats without storage armrest 13. Unzip the armrest trim cover zipper, peal the trim cover back and remove the hog rings and the trim cover. All seats 14. To assemble, reverse the disassembly procedure. Seat Backrest - Rear SEAT BACKREST - REAR Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8007 Disassembly and Assembly 1. Remove the rear seat backrest. 2. Remove the head restraints (1 shown). - Push the 2 release tabs and remove the head restraint. 3. NOTE: - The inboard and outboard head restraint guides are not interchangeable. - If necessary, install new head restraint guides. Push the release tabs and pull the head restraint guides out of the frame tube (trim cover and foam pad removed for clarity). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8008 4. Release the backrest J-clips. 5. CAUTION: Use care when separating the seat backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat backrest foam pad. Separate the hook-and-loop fasteners. 6. Remove the hog rings. Remove the seat trim cover and the backrest foam pad. 7. NOTE: If necessary, install new plastic lock clips. Push the release tabs and remove the 3 backrest plastic lock clips (one shown). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8009 8. To assemble, reverse the disassembly procedure. Seat Backrest - Front, With Seat Integrated Restraints (SIR) SEAT BACKREST - FRONT, WITH SEAT INTEGRATED RESTRAINTS (SIR) Special Tool(s) Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8010 Disassembly and Assembly WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - LH shown, RH similar. All seats Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8011 1. Remove the seat. 2. Remove the seat backrest. 3. Push the 2 release tabs and remove the head restraint. 4. Remove the safety belt tower cover. - Remove the 2 screw covers, 4 screws and safety belt tower cover. 5. Remove the screw and separate the safety belt guide. 6. Lift the backrest trim cover material and release the backrest J-clip. 7. CAUTION: Use care when separating the seat backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat backrest foam. Invert the backrest trim cover, separate the hook-and-loop fasteners and remove the hog rings on the front of the backrest foam pad. 8. If equipped with map pockets, remove the hog rings from the rear of the backrest. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8012 9. NOTE: - The inboard and outboard head restraint guides are not interchangeable. - If necessary, install new head restraint guides. Access and remove the 2 head restraint guides. Release the locking tabs and pull the head restraint guides out of the backrest frame tubes. 10. Remove the backrest trim cover. Heated seat 11. Disconnect the backrest heater mat electrical connector. 12. CAUTION: If installing a new backrest foam pad, the heater mat cannot be reused. A new heater mat must be installed. Failure to follow this instruction can result in component or system failure. NOTE: A new heater mat can be attached to a foam pad where an old heater mat was removed but a used heater mat should not be reattached to any foam pad. To service the backrest heater mat, peel and remove from the backrest foam pad. If reusing the backrest foam pad, take precautions not to remove excess foam when peeling off the heater mat. If the foam pad is damaged, install a new foam pad and a new heater mat. - For installation, align and lay the heater mat flat on the foam pad surface without any wrinkles and correctly tuck into the valley of the foam pad. All seats 13. Remove the backrest foam pad. 14. Remove the bolt and the safety belt retractor. - To install, tighten to 35 Nm (26 lb-ft). 15. Remove the bolt and the safety belt tower bracket. - To install, tighten to 60 Nm (44 lb-ft). 16. Detach the lumbar assembly retainer clips. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8013 17. Remove the lumbar assembly. 18. Remove the 2 backrest frame-to-recliner bolts and recliner. - To install, tighten to 55 Nm (41 lb-ft). 19. Remove the recliner strut. 20. To assemble, reverse the disassembly procedure. 21. Install the seat. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 22. WARNING: - Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. - Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. - To prevent system failure, the following precautions must be taken before carrying out the occupant classification sensor (OCS) system reset. Make sure the voltage to the occupant classification system module (OCSM) is above 8.0 volts and less than 18.0 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. NOTE: If the first attempt to carry out the OCS system reset is unsuccessful, a second attempt must made. If the second attempt to carry out the OCS system reset is unsuccessful, a new OCS system service kit must be installed. Carry out the OCS system reset command using the scan tool. 23. Cycle the ignition switch from ON to OFF. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8014 24. NOTE: The ignition switch must be cycled after the OCS system reset. Cycle the ignition switch from OFF to ON. All seats 25. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front Seat Cover: Service and Repair Seat Backrest Cover - Front SEAT BACKREST COVER - FRONT Exploded View Front Seat Backrest - With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8019 Front Seat Backrest - Without Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8020 Front Seat Cushion - Driver (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8021 Front Seat Cushion - Driver (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8022 Front Seat Cushion - Passenger (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8023 Front Seat Cushion - Passenger (Part 2) Special Tool(s) Special Tool(s) Removal and Installation WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - LH shown, RH similar. All seats 1. Remove the front seat. 2. Remove the front seat backrest. 3. Push the 2 release tabs and remove the head restraint. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8024 Seat with seat integrated restraints (SIR) 4. Remove the safety belt tower cover. - Remove the 2 screw covers, 4 screws and the safety belt tower cover. All seats 5. Lift the backrest trim cover material and release the backrest J-clip. 6. CAUTION: Use care when separating the seat backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat backrest foam. Invert the backrest trim cover, separate the hook-and-loop fasteners and remove the hog rings on the front of the backrest foam pad. 7. If equipped with map pockets, remove the hog rings from the rear of the backrest. 8. NOTE: - The inboard and outboard head restraint guides are not interchangeable. - If necessary, install new head restraint guides. Access and remove the 2 head restraint guides. Release the locking tabs and pull the head restraint guides out of the backrest frame tubes. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8025 9. Remove the backrest trim cover. 10. To install, reverse the removal procedure. 11. Install the front seat backrest 12. Install the front seat. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 13. WARNING: - Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. - Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. - To prevent system failure, the following precautions must be taken before carrying out the occupant classification sensor (OCS) system reset: Make sure the voltage to the occupant classification system module (OCSM) is above 8.0 volts and less than 18.0 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process NOTE: If the first attempt to carry out the OCS system reset is unsuccessful, a second attempt must be made. If the second attempt to carry out the OCS system reset is unsuccessful, a new OCS system service kit must be installed. Carry out the OCS system reset command using the scan tool. 14. Cycle the ignition switch from ON to OFF. 15. NOTE: The ignition switch must be cycled after the OCS system reset. Cycle the ignition switch from OFF to ON. All seats 16. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8026 position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8027 Seat Cover: Service and Repair Seat Cushion Cover - Front SEAT CUSHION COVER - FRONT Exploded View Front Seat Backrest - With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8028 Front Seat Backrest - Without Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8029 Front Seat Cushion - Driver (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8030 Front Seat Cushion - Driver (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8031 Front Seat Cushion - Passenger (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8032 Front Seat Cushion - Passenger (Part 2) Special Tool(s) Special Tool(s) Removal and Installation WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. CAUTION: - It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. - Do not install a new heater mat on a front passenger seat cushion. If a new cushion heater mat is needed on the front passenger seat, an occupant classification sensor (OCS) system service kit equipped with a heater mat must be installed. Failure to follow this instruction may result in incorrect operation of the OCS system. NOTE: - Occupant classification sensor (OCS) system components (seat wiring harness, seat cushion frame, seat cushion foam pad, bladder with pressure sensor and occupant classification system module [OCSM]) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, an OCS system service kit (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness and OCSM) must be installed as an assembly. - To identify between a production OCS system and a OCS system service kit, inspect the OCSM electrical connector. A production OCS system allows the disconnection of the OCSM electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8033 An OCS system service kit has the electrical connector glued to the OCSM, it cannot and should not be disconnected or altered. - When installing a new OCS system service kit, refer to Air Bag Systems for the OCS removal and installation procedure. - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Power seat shown, manual seat similar. All seats 1. Remove the seat. 2. If equipped, disconnect the seat control switch electrical connector. 3. NOTE: To aid cushion removal, position the backrest rearward before removing the recliner handle. Remove the recliner handle. Release the clip at the rear of side shield by detaching the clip from the metal bracket on the track. Partially flex the side shield at the rear to obtain access to the recliner handle clip. Remove the recliner handle clip (shown removed for clarity) and the recliner handle. 4. If equipped, adjust the lumbar until fully relaxed and remove the lumbar adjust knob. 5. Remove the side shield control panel. 6. If equipped, disconnect the memory SET switch electrical connector. 7. Release the pin-type retainer at the front of the side shield. 8. Remove the 3 screws and side shield. 9. CAUTION: To prevent component damage and avoid setting diagnostic trouble codes (DTCs), the following precautions must be taken: - The position assurance locking wedge must be in the released position when inserting or removing the electrical connector from the safety belt buckle and pretensioner. - Do not install the electrical connector by pushing on the position assurance locking wedge. - Make sure the electrical connector and position assurance locking wedge are fully seated after connecting to the safety belt buckle and pretensioner. Release the position assurance locking wedge on the safety belt buckle and pretensioner electrical connector. 10. NOTE: If equipped with manual lumbar, make sure the wire harness is routed above the manual lumbar cable. Disconnect the safety belt buckle and pretensioner electrical connector. 11. Disconnect the safety belt buckle switch electrical connector. 12. If equipped, disconnect the backrest heater mat electrical connector. 13. If equipped with seat integrated restraints (SIR), remove the safety belt anchor nut. - To install, tighten to 55 Nm (41 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8034 - If passenger seat, disconnect the belt tension sensor (BTS) electrical connector. 14. If equipped, disconnect the power seat track electrical connector and release any pin-type retainers attached to the seat cushion frame. 15. If equipped, disconnect the 3 memory seat position sensor electrical connectors (1 shown) and detach the wiring harness from the cushion frame. 16. If equipped with manual lumbar, release the rear inboard cushion trim cover J-clip and note the lumbar cable routing for installation. 17. Remove 4 nuts and cushion frame. - To install, tighten to 25 Nm (18 lb-ft). - Disconnect and detach all remaining electrical connectors and pin-type retainers attached to the seat cushion frame. 18. Release the cushion trim cover J-clips. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8035 19. Remove the hog rings and cushion trim cover. 20. To install, reverse the removal procedure. - Make sure the safety belts and buckles are accessible to the occupants after installation. - Verify the safety belt retractor operates without excessive effort or binding. 21. Install the seat. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 22. WARNING: - Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. - Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. - To prevent system failure, the following precautions must be taken before carrying out the occupant classification sensor (OCS) system reset: Make sure the voltage to the occupant classification system module (OCSM) is above 8.0 volts and less than 18.0 volts. - Make sure the OCS system is not at a temperature below 6C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8036 NOTE: If the first attempt to carry out the OCS system reset is unsuccessful, a second attempt must be made. If the second attempt to carry out the OCS system reset is unsuccessful, a new OCS system service kit must be installed. Carry out the OCS system reset command using the scan tool. 23. Cycle the ignition switch from ON to OFF. 24. NOTE: The ignition switch must be cycled after the OCS system reset. Cycle the ignition switch from OFF to ON. All seats 25. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8037 Seat Cover: Service and Repair Seat Backrest Cover - Front, 20 Percent SEAT BACKREST COVER - FRONT, 20 PERCENT Exploded View Front Seat Backrest - 20 Persent, With Storage, SuperCab And SuperCrew (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8038 Front Seat Backrest - 20 Persent, With Storage, SuperCab And SuperCrew (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8039 Front Seat Backrest - 20 Persent, Without Storage (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8040 Front Seat Backrest - 20 Persent, Without Storage (Part 2) Front Seat Cushion - 20 Percent Removal and Installation 1. Remove the 20 percent seat. 2. Remove the LH side shield pin-type retainer, screw and shield. 3. Remove the RH upper side shield screw and shield. 4. Remove the LH backrest bracket pivot bolt and pivot bolt bushing. - To install, tighten to 35 Nm (26 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8041 5. Remove the 2 RH upper adjustable backrest bracket bolts and the adjustable backrest. - To install, tighten to 35 Nm (26 lb-ft). 6. Unzip the armrest trim cover zipper, peal the trim cover back and remove the hog rings and the trim cover. 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8042 Seat Cover: Service and Repair Seat Cushion Cover - Front, 20 Percent SEAT CUSHION COVER - FRONT, 20 PERCENT Exploded View Front Seat Backrest - 20 Persent, With Storage, SuperCab And SuperCrew (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8043 Front Seat Backrest - 20 Persent, With Storage, SuperCab And SuperCrew (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8044 Front Seat Backrest - 20 Persent, Without Storage (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8045 Front Seat Backrest - 20 Persent, Without Storage (Part 2) Front Seat Cushion - 20 Percent Removal and Installation 1. Remove the 20 percent seat cushion. 2. Release the J-clips and remove the seat cushion pan. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8046 3. Remove the 6 hog rings (3 shown) and remove the 20 percent seat trim cover from the seat cushion foam pad. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8047 Seat Cover: Service and Repair Seat Backrest Cover - Front SEAT BACKREST COVER - FRONT Exploded View Front Seat Backrest - With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8048 Front Seat Backrest - Without Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8049 Front Seat Cushion - Driver (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8050 Front Seat Cushion - Driver (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8051 Front Seat Cushion - Passenger (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8052 Front Seat Cushion - Passenger (Part 2) Special Tool(s) Special Tool(s) Removal and Installation WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - LH shown, RH similar. All seats 1. Remove the front seat. 2. Remove the front seat backrest. 3. Push the 2 release tabs and remove the head restraint. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8053 Seat with seat integrated restraints (SIR) 4. Remove the safety belt tower cover. - Remove the 2 screw covers, 4 screws and the safety belt tower cover. All seats 5. Lift the backrest trim cover material and release the backrest J-clip. 6. CAUTION: Use care when separating the seat backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat backrest foam. Invert the backrest trim cover, separate the hook-and-loop fasteners and remove the hog rings on the front of the backrest foam pad. 7. If equipped with map pockets, remove the hog rings from the rear of the backrest. 8. NOTE: - The inboard and outboard head restraint guides are not interchangeable. - If necessary, install new head restraint guides. Access and remove the 2 head restraint guides. Release the locking tabs and pull the head restraint guides out of the backrest frame tubes. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8054 9. Remove the backrest trim cover. 10. To install, reverse the removal procedure. 11. Install the front seat backrest 12. Install the front seat. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 13. WARNING: - Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. - Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. - To prevent system failure, the following precautions must be taken before carrying out the occupant classification sensor (OCS) system reset: Make sure the voltage to the occupant classification system module (OCSM) is above 8.0 volts and less than 18.0 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process NOTE: If the first attempt to carry out the OCS system reset is unsuccessful, a second attempt must be made. If the second attempt to carry out the OCS system reset is unsuccessful, a new OCS system service kit must be installed. Carry out the OCS system reset command using the scan tool. 14. Cycle the ignition switch from ON to OFF. 15. NOTE: The ignition switch must be cycled after the OCS system reset. Cycle the ignition switch from OFF to ON. All seats 16. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8055 position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Seat Cushion Cover - Front SEAT CUSHION COVER - FRONT Exploded View Front Seat Backrest - With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8056 Front Seat Backrest - Without Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8057 Front Seat Cushion - Driver (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8058 Front Seat Cushion - Driver (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8059 Front Seat Cushion - Passenger (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8060 Front Seat Cushion - Passenger (Part 2) Special Tool(s) Special Tool(s) Removal and Installation WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. CAUTION: - It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. - Do not install a new heater mat on a front passenger seat cushion. If a new cushion heater mat is needed on the front passenger seat, an occupant classification sensor (OCS) system service kit equipped with a heater mat must be installed. Failure to follow this instruction may result in incorrect operation of the OCS system. NOTE: - Occupant classification sensor (OCS) system components (seat wiring harness, seat cushion frame, seat cushion foam pad, bladder with pressure sensor and occupant classification system module [OCSM]) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, an OCS system service kit (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness and OCSM) must be installed as an assembly. - To identify between a production OCS system and a OCS system service kit, inspect the OCSM electrical connector. A production OCS system allows the disconnection of the OCSM electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8061 An OCS system service kit has the electrical connector glued to the OCSM, it cannot and should not be disconnected or altered. - When installing a new OCS system service kit, refer to Air Bag Systems for the OCS removal and installation procedure. - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Power seat shown, manual seat similar. All seats 1. Remove the seat. 2. If equipped, disconnect the seat control switch electrical connector. 3. NOTE: To aid cushion removal, position the backrest rearward before removing the recliner handle. Remove the recliner handle. Release the clip at the rear of side shield by detaching the clip from the metal bracket on the track. Partially flex the side shield at the rear to obtain access to the recliner handle clip. Remove the recliner handle clip (shown removed for clarity) and the recliner handle. 4. If equipped, adjust the lumbar until fully relaxed and remove the lumbar adjust knob. 5. Remove the side shield control panel. 6. If equipped, disconnect the memory SET switch electrical connector. 7. Release the pin-type retainer at the front of the side shield. 8. Remove the 3 screws and side shield. 9. CAUTION: To prevent component damage and avoid setting diagnostic trouble codes (DTCs), the following precautions must be taken: - The position assurance locking wedge must be in the released position when inserting or removing the electrical connector from the safety belt buckle and pretensioner. - Do not install the electrical connector by pushing on the position assurance locking wedge. - Make sure the electrical connector and position assurance locking wedge are fully seated after connecting to the safety belt buckle and pretensioner. Release the position assurance locking wedge on the safety belt buckle and pretensioner electrical connector. 10. NOTE: If equipped with manual lumbar, make sure the wire harness is routed above the manual lumbar cable. Disconnect the safety belt buckle and pretensioner electrical connector. 11. Disconnect the safety belt buckle switch electrical connector. 12. If equipped, disconnect the backrest heater mat electrical connector. 13. If equipped with seat integrated restraints (SIR), remove the safety belt anchor nut. - To install, tighten to 55 Nm (41 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8062 - If passenger seat, disconnect the belt tension sensor (BTS) electrical connector. 14. If equipped, disconnect the power seat track electrical connector and release any pin-type retainers attached to the seat cushion frame. 15. If equipped, disconnect the 3 memory seat position sensor electrical connectors (1 shown) and detach the wiring harness from the cushion frame. 16. If equipped with manual lumbar, release the rear inboard cushion trim cover J-clip and note the lumbar cable routing for installation. 17. Remove 4 nuts and cushion frame. - To install, tighten to 25 Nm (18 lb-ft). - Disconnect and detach all remaining electrical connectors and pin-type retainers attached to the seat cushion frame. 18. Release the cushion trim cover J-clips. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8063 19. Remove the hog rings and cushion trim cover. 20. To install, reverse the removal procedure. - Make sure the safety belts and buckles are accessible to the occupants after installation. - Verify the safety belt retractor operates without excessive effort or binding. 21. Install the seat. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 22. WARNING: - Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. - Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. - To prevent system failure, the following precautions must be taken before carrying out the occupant classification sensor (OCS) system reset: Make sure the voltage to the occupant classification system module (OCSM) is above 8.0 volts and less than 18.0 volts. - Make sure the OCS system is not at a temperature below 6C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8064 NOTE: If the first attempt to carry out the OCS system reset is unsuccessful, a second attempt must be made. If the second attempt to carry out the OCS system reset is unsuccessful, a new OCS system service kit must be installed. Carry out the OCS system reset command using the scan tool. 23. Cycle the ignition switch from ON to OFF. 24. NOTE: The ignition switch must be cycled after the OCS system reset. Cycle the ignition switch from OFF to ON. All seats 25. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Seat Backrest Cover - Front, 20 Percent SEAT BACKREST COVER - FRONT, 20 PERCENT Exploded View Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8065 Front Seat Backrest - 20 Persent, With Storage, SuperCab And SuperCrew (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8066 Front Seat Backrest - 20 Persent, With Storage, SuperCab And SuperCrew (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8067 Front Seat Backrest - 20 Persent, Without Storage (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8068 Front Seat Backrest - 20 Persent, Without Storage (Part 2) Front Seat Cushion - 20 Percent Removal and Installation 1. Remove the 20 percent seat. 2. Remove the LH side shield pin-type retainer, screw and shield. 3. Remove the RH upper side shield screw and shield. 4. Remove the LH backrest bracket pivot bolt and pivot bolt bushing. - To install, tighten to 35 Nm (26 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8069 5. Remove the 2 RH upper adjustable backrest bracket bolts and the adjustable backrest. - To install, tighten to 35 Nm (26 lb-ft). 6. Unzip the armrest trim cover zipper, peal the trim cover back and remove the hog rings and the trim cover. 7. To install, reverse the removal procedure. Seat Cushion Cover - Front, 20 Percent SEAT CUSHION COVER - FRONT, 20 PERCENT Exploded View Front Seat Backrest - 20 Persent, With Storage, SuperCab And SuperCrew (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8070 Front Seat Backrest - 20 Persent, With Storage, SuperCab And SuperCrew (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8071 Front Seat Backrest - 20 Persent, Without Storage (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8072 Front Seat Backrest - 20 Persent, Without Storage (Part 2) Front Seat Cushion - 20 Percent Removal and Installation 1. Remove the 20 percent seat cushion. 2. Release the J-clips and remove the seat cushion pan. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8073 3. Remove the 6 hog rings (3 shown) and remove the 20 percent seat trim cover from the seat cushion foam pad. 4. To install, reverse the removal procedure. Seat Backrest Cover - Rear SEAT BACKREST COVER - REAR Exploded View Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8074 Rear Seat Cushion (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8075 Rear Seat Cushion (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8076 Rear Seat Backrest Removal and Installation 1. Remove the rear seat backrest. 2. Remove the head restraints (1 shown). - Push the 2 release tabs and remove the head restraint. 3. NOTE: - The inboard and outboard head restraint guides are not interchangeable. - If necessary, install new head restraint guides. Push the release tabs and pull the head restraint guides out of the frame tube (trim cover and foam pad removed for clarity). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8077 4. Release the backrest J-clips. 5. CAUTION: Use care when separating the seat backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat backrest foam pad. Separate the hook-and-loop fasteners. 6. Remove the hog rings and backrest trim cover. 7. To install, reverse the removal procedure. Seat Cushion Cover - Rear SEAT CUSHION COVER - REAR Exploded View Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8078 Rear Seat Cushion (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8079 Rear Seat Cushion (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8080 Rear Seat Backrest Removal and Installation All seats 1. Remove the rear seat cushion. 2. Remove the 4 rear seat LATCH bolts and LATCH. - To install, tighten to 6 Nm (53 lb-in). 3. Remove the 60/40 retention clip. 4. Remove the center support riser. 60 percent seat 5. Remove the 60 percent support riser bolt. - To install, tighten to 33 Nm (24 lb-ft). 6. Remove the 60 percent support riser pivot bolt and bushing. - To install, tighten to 33 Nm (24 lb-ft). 7. Remove the left support riser. 8. Remove the 60 percent seat cushion latch handle screw and handle. 9. Remove the 60 percent seat cushion latch cover screw and cover. 10. Remove the 60 percent seat latch cushion bolt and latch. - To install, tighten to 26 Nm (19 lb-ft). 11. CAUTION: Use care when separating the seat cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8081 from the seat cushion foam pad. Separate the hook-and-loop strips. 12. Remove the hog rings and 60 percent cushion trim cover. 40 percent seat 13. Remove the 40 percent support riser bolt. - To install, tighten to 33 Nm (24 lb-ft). 14. Remove the 40 percent support riser pivot bolt, bushing and right support riser. - To install, tighten to 33 Nm (24 lb-ft). 15. Remove the 40 percent seat cushion latch handle screw and handle. 16. Remove the 40 percent seat cushion latch cover screw and cover. 17. Remove the 40 percent seat cushion latch bolt and latch. - To install, tighten to 26 Nm (19 lb-ft). 18. CAUTION: Use care when separating the seat cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion foam pad. Separate the hook-and-loop strips. 19. Remove the hog rings and 40 percent cushion trim cover. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 8082 All seats 20. To assemble, reverse the disassembly procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front Seat Cushion: Service and Repair Seat Cushion - Front SEAT CUSHION - FRONT Special Tool(s) Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 8087 Front Seat Cushion - Driver (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 8088 Front Seat Cushion - Driver (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 8089 Front Seat Cushion - Passenger (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 8090 Front Seat Cushion - Passenger (Part 2) Disassembly and Assembly WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. CAUTION: - It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. - Do not install a new heater mat on a front passenger seat cushion. If a new cushion heater mat is needed on the front passenger seat, an occupant classification sensor (OCS) system service kit equipped with a heater mat must be installed. Failure to follow this instruction may result in incorrect operation of the OCS system. NOTE: - Occupant classification sensor (OCS) system components (seat wiring harness, seat cushion frame, seat cushion foam pad, bladder with pressure sensor and occupant classification system module [OCSM]) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, an OCS system service kit (seat cushion frame, seat cushion foam pad, bladder with pressure sensor, seat wiring harness and OCSM) must be installed as an assembly. - To identify between a production OCS system and a OCS system service kit, inspect the OCSM electrical connector. A production OCS system allows the disconnection of the OCSM electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 8091 An OCS system service kit has the electrical connector glued to the OCSM, it cannot and should not be disconnected or altered. - When installing a new OCS system service kit, refer to Air Bag Systems for the OCS removal and installation procedure. - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - For vehicles with power seats, position the seat cushion to its lowest position before disconnecting the power seat. - Power seat shown, manual seat similar. All seats 1. Remove the seat. 2. If equipped, disconnect the seat control switch electrical connector. 3. NOTE: To aid cushion removal, position the backrest rearward before removing the recliner handle. Remove the recliner handle. Release the clip at the rear of side shield by detaching the clip from the metal bracket on the track. Partially flex the side shield at the rear to obtain access to the recliner handle clip. Remove the recliner handle clip (removed for clarity) and the recliner handle. 4. If equipped, adjust the lumbar until fully relaxed and remove the lumbar adjust knob. 5. If equipped, remove the seat control switch knob. 6. Remove the side shield control panel. 7. If equipped, disconnect the memory SET switch electrical connector. 8. Release the pin-type retainer at the front of the side shield. 9. Remove the 3 screws and side shield. 10. CAUTION: To prevent component damage and avoid setting diagnostic trouble codes (DTCs), the following precautions must be taken: - The position assurance locking wedge must be in the released position when inserting or removing the electrical connector from the safety belt buckle and pretensioner. - Do not install the electrical connector by pushing on the position assurance locking wedge. - Make sure the electrical connector and position assurance locking wedge are fully seated after connecting to the safety belt buckle and pretensioner. Release the position assurance locking wedge on the safety belt buckle and pretensioner electrical connector. 11. NOTE: If equipped with manual lumbar, make sure the wire harness is routed above the manual lumbar cable. Disconnect the safety belt buckle and pretensioner electrical connector. 12. Disconnect the safety belt buckle switch electrical connector. 13. Remove the nut and the safety belt buckle and pretensioner. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 8092 - To install, tighten to 55 Nm (41 lb-ft). - The anti-rotation tab must be correctly aligned for correct installation. - When installing, pull the safety belt buckle through the anti-rattle strap located on the side of the seat. 14. If equipped, disconnect the backrest heater mat electrical connector. 15. If equipped with seat integrated restraints (SIR), remove the safety belt anchor nut. - To install, tighten to 55 Nm (41 lb-ft). - If passenger seat, disconnect the belt tension sensor (BTS) electrical connector. 16. If equipped, disconnect the power seat track electrical connector and release any pin-type retainers attached to the seat cushion frame. 17. If equipped, disconnect the 3 memory seat position sensor electrical connectors (one shown) and detach the wiring harness from the cushion frame. 18. If equipped with manual lumbar, release the rear inboard cushion trim cover J-clip and note the lumbar cable routing for installation. 19. Remove 4 nuts and cushion frame. - To install, tighten to 25 Nm (18 lb-ft). - Disconnect and detach all remaining electrical connectors and pin-type retainers attached to the seat cushion frame. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 8093 Passenger seats 20. For disassembly of the passenger seat cushion assembly (cushion trim cover, foam pad, OCS bladder with pressure sensor, OCSM and cushion frame), refer to the Occupant Classification Sensor removal and installation procedure in Air Bag Systems. Driver seats 21. Release the cushion trim cover J-clips. 22. Remove the hog rings and the cushion trim cover. 23. Remove the hog rings and cushion foam pad from the seat cushion frame. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 8094 24. CAUTION: If installing a new cushion foam pad, the heater mat cannot be reused. A new heater mat must be installed. Failure to follow this instruction can result in component or system failure. NOTE: A new heater mat can be attached to a foam pad where an old heater mat was removed but a used heater mat should not be reattached to any foam pad. To service the cushion heater mat, peel and remove the cushion heater mat from the cushion foam pad. If reusing the cushion foam pad, take precautions not to remove excess foam when peeling off the heater mat. If the foam pad is damaged, install a new foam pad and a new heater mat. - For installation, align and lay the heater mat flat on the foam pad surface without any wrinkles and correctly tuck into the valley of the foam pad. All seats 25. To assemble, reverse the disassembly procedure. - Make sure the safety belts and buckles are accessible to the occupants after installation. - Verify the safety belt retractor operates without excessive effort or binding. 26. Install the seat. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 27. WARNING: - Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. - Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. CAUTION: To prevent system failure, it is necessary to carry out the occupant classification sensor (OCS) system reset of the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed or an OCS system service kit is installed. A scan tool is used to trigger the command to carry out the OCS system reset. - To prevent system failure, the following precautions must be taken before carrying out the occupant classification sensor (OCS) system reset: Make sure the voltage to the occupant classification system module (OCSM) is above 8.0 volts and less than 18.0 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. NOTE: If the first attempt to carry out the OCS system reset is unsuccessful, a second attempt must be made. If the second attempt to carry out the OCS system reset is unsuccessful, a new OCS system service kit must be installed. Carry out the OCS system reset command using the scan tool. 28. Cycle the ignition switch from ON to OFF. 29. NOTE: The ignition switch must be cycled after the OCS system reset. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 8095 Cycle the ignition switch from OFF to ON. All seats 30. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 8096 Seat Cushion: Service and Repair Seat Cushion - Front, 20 Percent SEAT CUSHION - FRONT, 20 PERCENT Disassembly and Assembly 1. Remove the 20 percent seat cushion. 2. Release the J-clips and remove the seat cushion pan. 3. Remove the 6 hog rings (3 shown) and remove the 20 percent seat trim cover from the seat cushion foam pad. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 8097 4. To assemble, reverse the disassembly procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 8098 Seat Cushion: Service and Repair Seat Cushion - Rear SEAT CUSHION - REAR Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 8099 Part 2 Disassembly and Assembly All seats 1. Remove the rear seat cushion. 2. Remove the 4 rear seat LATCH bolts and LATCH. - To install, tighten to 6 Nm (53 lb-in). 3. Remove the 60/40 retention clip. 4. Remove the center support riser. 60 percent seat 5. Remove the 60 percent support riser bolt. - To install, tighten to 33 Nm (24 lb-ft). 6. Remove the 60 percent support riser pivot bolt and bushing. - To install, tighten to 33 Nm (24 lb-ft). 7. Remove the left support riser. 8. Remove the 60 percent seat cushion latch handle screw and handle. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 8100 9. Remove the 60 percent seat cushion latch cover screw and cover. 10. Remove the 60 percent seat latch cushion bolt and latch. - To install, tighten to 26 Nm (19 lb-ft). 11. CAUTION: Use care when separating the seat cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion foam pad. Separate the hook-and-loop fasteners. 12. Remove the 60 percent cushion trim cover. - Remove the hog rings and remove the seat trim cover. 13. Remove the 60 percent cushion foam pad. 14. Remove the 60 percent inboard pivot bushing. 40 percent seat 15. Remove the 40 percent support riser bolt. - To install, tighten to 33 Nm (24 lb-ft). 16. Remove the 40 percent support riser pivot bolt, bushing and right support riser. - To install, tighten to 33 Nm (24 lb-ft). 17. Remove the 40 percent seat cushion latch handle screw and handle. 18. Remove the 40 percent seat cushion latch cover screw and cover. 19. Remove the 40 percent seat cushion latch bolt and latch. - To install, tighten to 26 Nm (19 lb-ft). 20. CAUTION: Use care when separating the seat cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion foam pad. Separate the hook-and-loop fasteners. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion - Front > Page 8101 21. Remove the 40 percent cushion trim cover. - Remove the hog rings and remove the seat cushion trim cover. 22. Remove the 40 percent cushion foam pad. 23. Remove the 40 percent inboard pivot bushing. All seats 24. To assemble, reverse the disassembly procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions Seat Heater: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8106 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8107 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8108 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8109 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8110 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8111 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8112 Seat Heater: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8113 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8114 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8115 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8116 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8117 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8118 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8119 Seat Heater: Connector Views C334 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8120 C364 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8121 C335 C365 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8122 Seat Heater: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 119-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 8123 119-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Heated Seat Module, Driver Side Front View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Heated Seat Module, Driver Side Front > Page 8128 View 151-29 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Heated Seat Module, Passenger Side Front C329 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Heated Seat Module, Passenger Side Front > Page 8131 C359 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 8132 Seat Heater Control Module: Service and Repair HEATED SEAT MODULE Exploded View Front Seat Backrest - With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 8133 Front Seat Backrest - Without Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 8134 Front Seat Cushion - Driver (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 8135 Front Seat Cushion - Driver (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 8136 Front Seat Cushion - Passenger (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 8137 Front Seat Cushion - Passenger (Part 2) Removal and Installation WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the seat. 2. Disconnect the heated seat module electrical connector. 3. Detach and remove the heated seat module from the seat cushion frame 4. To install, reverse the removal procedure. 5. Install the seat. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair Seat Heater Switch: Service and Repair SEAT CONTROL SWITCH Exploded View Front Seat Backrest - With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Page 8141 Front Seat Backrest - Without Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Page 8142 Front Seat Cushion - Driver (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Page 8143 Front Seat Cushion - Driver (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Page 8144 Front Seat Cushion - Passenger (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Page 8145 Front Seat Cushion - Passenger (Part 2) Removal and Installation 1. Disconnect the seat control switch electrical connector. 2. Remove the recliner handle. - Release the clip at the rear of side shield by detaching the clip from the metal bracket on the track. Partially flex the side shield at the rear to obtain access to the recliner handle clip. Remove the recliner handle clip (shown removed for clarity) and the recliner handle. 3. If equipped, remove the lumbar adjust knob. 4. Remove the seat control switch knob. 5. Remove the side shield control panel. 6. Remove the 2 screws and the seat control switch. 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual Seat Track: Service and Repair Seat Track - Manual SEAT TRACK - MANUAL Exploded View Front Seat Backrest - With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 8150 Front Seat Backrest - Without Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 8151 Front Seat Cushion - Driver (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 8152 Front Seat Cushion - Driver (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 8153 Front Seat Cushion - Passenger (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 8154 Front Seat Cushion - Passenger (Part 2) Special Tool(s) Special Tool(s) Removal and Installation WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All seats 1. Remove the seat. 2. Remove the front seat backrest. Regular cab and SuperCab seats 3. NOTE: RH shown, LH similar. Remove the 6 front seat frame rear support bolts and the support. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 8155 - When installing, install the bolts and tighten in the sequence shown. - To install, tighten to 30 Nm (22 lb-ft). Driver seat 4. Remove the 2 nuts and seat position sensor. - Disconnect the seat position sensor electrical connector. All seats 5. NOTE: Driver seat without seat integrated restraints (SIR) shown, others similar. Remove the seat track control handle retaining clip. 6. NOTE: Driver seat without SIR shown, others similar. Detach the seat track control handle and remove the outboard seat track. 7. NOTE: Driver seat without SIR shown, others similar. Rotate the seat track adjust handle to relieve the spring tension and detach the seat track adjust handle from the inboard seat track. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 8156 8. To install, reverse the removal procedure. 9. Install the seat. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 10. WARNING: - Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. - Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. - To prevent system failure, the following precautions must be taken before carrying out the occupant classification sensor (OCS) system reset: Make sure the voltage to the occupant classification system module (OCSM) is above 8.0 volts and less than 18.0 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. NOTE: If the first attempt to carry out the OCS system reset is unsuccessful, a second attempt must be made. If the second attempt to carry out the OCS system reset is unsuccessful, a new OCS system service kit must be installed. Carry out the OCS system reset command using the scan tool. 11. Cycle the ignition switch from ON to OFF. 12. NOTE: The ignition switch must be cycled after the OCS system reset. Cycle the ignition switch from OFF to ON. All seats 13. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 8157 diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 8158 Seat Track: Service and Repair Seat Track - Power SEAT TRACK - POWER Exploded View Front Seat Backrest - With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 8159 Front Seat Backrest - Without Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 8160 Front Seat Cushion - Driver (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 8161 Front Seat Cushion - Driver (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 8162 Front Seat Cushion - Passenger (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 8163 Front Seat Cushion - Passenger (Part 2) Special Tool(s) Special Tool(s) Removal and Installation WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All seats 1. Remove the seat. 2. Remove the seat backrest. Regular cab and SuperCab seats 3. Remove the 6 front seat frame rear support bolts and the support. - When installing, install the bolts and tighten in the sequence shown. - To install, tighten to 30 Nm (22 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 8164 Driver seat 4. Remove the 2 nuts and seat position sensor. - Disconnect the seat position sensor electrical connector. All seats 5. To install, reverse the removal procedure. 6. Install the seat. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 7. WARNING: - Install a new occupant classification sensor (OCS) system service kit as a complete assembly. Never install only part of the kit components. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. - Make sure the front passenger seat repair is complete, the seat and all attached components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out the System Reset. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a crash. CAUTION: It is necessary to carry out the occupant classification sensor (OCS) system reset when a front passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset command. Failure to follow this instruction may result in system failure and the incorrect operation of the OCS system. - To prevent system failure, the following precautions must be taken before carrying out the occupant classification sensor (OCS) system reset: Make sure the voltage to the occupant classification system module (OCSM) is above 8.0 volts and less than 18.0 volts. - Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when initiating the OCS system reset process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C (42°F to 97°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before carrying out the OCS system reset and nothing is placed on the seat during the process. - Make sure a minimum 8-second time period has passed after cycling the ignition switch ON before the carrying out the OCS system reset process. NOTE: If the first attempt to carry out the OCS system reset is unsuccessful, a second attempt must made. If the second attempt to carry out the OCS system reset is unsuccessful, a new OCS system service kit must be installed. Carry out the OCS system reset command using the scan tool. 8. Cycle the ignition switch from ON to OFF. 9. NOTE: The ignition switch must be cycled after the OCS system reset. Cycle the ignition switch from OFF to ON. All seats 10. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Manual > Page 8165 - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Diagrams C2090 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 8173 C2235 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side View 151-31 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side > Page 8178 View 151-30 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side C505 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side > Page 8181 C605 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side Power Door Lock Switch: Testing and Inspection Door Lock Switch, Driver Side Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Switch, Driver Side > Page 8184 Power Door Lock Switch: Testing and Inspection Door Lock Switch, Passenger Side Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Page 8185 Power Door Lock Switch: Service and Repair DOOR LOCK CONTROL SWITCH Removal and Installation 1. Remove the switch plate cover. 2. Disconnect the switch plate electrical connectors. 3. Release the door lock control switch tabs on the switch plate and remove the door lock control switch. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations View 151-30 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 8189 C527 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 8190 Power Mirror Switch: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 8191 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 8192 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH Removal and Installation 1. Remove the front door switch panel. - Disconnect the electrical connectors. 2. Remove the exterior mirror control switch. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Sensor View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Sensor > Page 8197 View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Front Height Sensor > Page 8198 View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor C372 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 8201 C383 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 8202 C373 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Seat Control Switch, Driver Side Front View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Seat Control Switch, Driver Side Front > Page 8207 View 151-29 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Passenger Side Front C330 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Seat Control Switch, Passenger Side Front > Page 8210 C369 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, Driver Side Front Power Seat Switch: Testing and Inspection Seat Control Switch, Driver Side Front Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, Driver Side Front > Page 8213 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, Driver Side Front > Page 8214 Power Seat Switch: Testing and Inspection Seat Control Switch, Passenger Side Front Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Control Switch, Driver Side Front > Page 8215 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair Seat Heater Switch: Service and Repair SEAT CONTROL SWITCH Exploded View Front Seat Backrest - With Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Page 8219 Front Seat Backrest - Without Seat Integrated Restraints (SIR) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Page 8220 Front Seat Cushion - Driver (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Page 8221 Front Seat Cushion - Driver (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Page 8222 Front Seat Cushion - Passenger (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Page 8223 Front Seat Cushion - Passenger (Part 2) Removal and Installation 1. Disconnect the seat control switch electrical connector. 2. Remove the recliner handle. - Release the clip at the rear of side shield by detaching the clip from the metal bracket on the track. Partially flex the side shield at the rear to obtain access to the recliner handle clip. Remove the recliner handle clip (shown removed for clarity) and the recliner handle. 3. If equipped, remove the lumbar adjust knob. 4. Remove the seat control switch knob. 5. Remove the side shield control panel. 6. Remove the 2 screws and the seat control switch. 7. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations View 151-28 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 8227 C3246 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations View 151-35 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 8231 C912 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 8232 Sunroof / Moonroof Switch: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 8233 Sunroof / Moonroof Switch: Service and Repair ROOF OPENING PANEL CONTROL SWITCH Removal and Installation 1. Remove the overhead console. 2. Disconnect the 2 overhead console electrical connectors. 3. Remove the 4 screws and light assembly from the overhead console. 4. Disengage the clips and remove the switch from the overhead console. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 8234 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation > Insulation Sound Proofing / Insulation: Description and Operation Insulation INSULATION Insulation is used as a sound-deadener to reduce exterior road and powertrain noises from the interior of the vehicle. Mastic insulators are also used as insulation. For information on the location of the mastic insulators, refer to Sound Proofing / Insulation. Insulation is installed: - under the roof. - above and below the instrument panel. - at the cowl side panels. - over the front and rear tunnel. - over the front and rear floor pans. It has heat-bondable mastic deadeners for improved noise, vibration and harshness (NVH) characteristics. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation > Insulation > Page 8239 Sound Proofing / Insulation: Description and Operation Sound Deadeners and Insulators SOUND DEADENERS AND INSULATORS WARNING: Always refer to Material Safety Data Sheet (MSDS) when handling chemicals and wear protective equipment as directed. Examples may include but are not limited to respirators and chemically resistant gloves. Failure to follow these instructions may result in serious personal injury. NOTICE: - Mastic is made of a combustible material and should be removed prior to carrying out welding procedures to the area. Heat zones from welding near the mastic can cause the mastic material to burn. - Corrosion protection must be restored to the area AFTER the mastic material is applied. Corrosion protection products may be wax based and loss of adhesion may occur. NOTE: - The following illustrations serve as a reference to indicate mastic patch (butyl pad) locations. Additional insulators and sound deadeners are used beyond those indicated in the illustration. - To restore the vehicle to design intent, missing or damaged sound deadeners and insulators should be replaced with the equivalent service replacement component. In instances where pumpable material is applied when manufactured and can not be duplicated, cut-to-fit mastic material is an acceptable replacement. Sound Deadeners and Insulators - Regular Cab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation > Insulation > Page 8240 Sound Deadeners and Insulators - SuperCab Sound Deadeners and Insulators - SuperCrew Cab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation > Insulation > Page 8241 Door 1. Whenever replacement of an existing mastic insulator is carried out, the surface must be thoroughly cleaned to make sure correct adhesion will occur. The surface should be 10°C (50°F) or greater before applying the mastic. The use of a heat gun to warm the metal surface will aid in adhesion. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair Tailgate Latch: Service and Repair TAILGATE LATCH Exploded View Removal and Installation 1. Open and support the tailgate. 2. Remove the 8 screws and the tailgate access panel. - To install, tighten to 5 Nm (44 lb-in). 3. Open the clip and release the tailgate latch actuating rod from the tailgate remote control. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Page 8246 4. Release the tailgate latch actuating rod locator from the tailgate. 5. Remove the tailgate latch bolt. - To install, tighten to 25 Nm (18 lb-ft). 6. Remove the tailgate latch bolt and the tailgate latch cable. - To install, tighten to 25 Nm (18 lb-ft). 7. Remove the tailgate latch. 8. To install, reverse the removal procedure. - Lubricate the tailgate latch after installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair Tailgate Release Handle: Service and Repair TAILGATE RELEASE HANDLE Exploded View Removal and Installation 1. Remove the tailgate latch remote control. 2. Disconnect the video camera connector, if equipped. 3. Remove the tailgate release handle. 4. To install, reverse the removal procedure. - Lubricate the tailgate release handle after installation. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Technical Service Bulletins > Customer Interest: > 07-25-2 > Dec > 07 > Body - Rattle Noise From Tailgate Tailgate Striker: Customer Interest Body - Rattle Noise From Tailgate TSB 07-25-2 12/24/07 TAILGATE STRIKER - NOISE/RATTLE FORD: 2004-2005 Explorer Sport Trac 2004-2008 F-150, F-Super Duty 2007-2008 Explorer Sport Trac LINCOLN: 2006-2008 Mark LT ISSUE Some 2004-2008 F-Super Duty and F-150, 2006-2008 Mark LT, and 2004-2005 and 2007-2008 Explorer Sport Trac vehicles with a customer complaint of a noise or rattle in the tailgate may have worn tailgate striker sleeves. This condition may be found on vehicles used in severe conditions such as fleet applications or repetitive rough road/off-road applications. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the tailgate striker bolt using a T50 Torx bit. 2. Replace the tailgate striker with a new striker. 3. Align the tailgate striker up/down to the tailgate latch and adjust in/out for margin flushness. 4. Torque the new tailgate striker to 30 lb-ft +/- 4 lb-ft (40 N.m +/- 6 N.m). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072502A 2004-2008 F-150, F-Super 0.2 Hr. Duty, 2006-2008 Mark LT and 2004-2005 and 2007-2008 Explorer Sport Trac: Replace One Tailgate Striker, Includes Time To Align Tailgate (Do Not Use With 40442A) 072502B 2004-2008 F-150, F-Super 0.3 Hr. Duty, 2006-2008 Mark LT and 2004-2005 and 2007-2008 Explorer Sport Trac: Replace Both Tailgate Strikers, Includes Time To Align Tailgate (Do Not Use With 40442A) DEALER CODING Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Technical Service Bulletins > Customer Interest: > 07-25-2 > Dec > 07 > Body - Rattle Noise From Tailgate > Page 8258 CONDITION BASIC PART NO. CODE 99404A42 30 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-25-2 > Dec > 07 > Body - Rattle Noise From Tailgate Tailgate Striker: All Technical Service Bulletins Body - Rattle Noise From Tailgate TSB 07-25-2 12/24/07 TAILGATE STRIKER - NOISE/RATTLE FORD: 2004-2005 Explorer Sport Trac 2004-2008 F-150, F-Super Duty 2007-2008 Explorer Sport Trac LINCOLN: 2006-2008 Mark LT ISSUE Some 2004-2008 F-Super Duty and F-150, 2006-2008 Mark LT, and 2004-2005 and 2007-2008 Explorer Sport Trac vehicles with a customer complaint of a noise or rattle in the tailgate may have worn tailgate striker sleeves. This condition may be found on vehicles used in severe conditions such as fleet applications or repetitive rough road/off-road applications. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the tailgate striker bolt using a T50 Torx bit. 2. Replace the tailgate striker with a new striker. 3. Align the tailgate striker up/down to the tailgate latch and adjust in/out for margin flushness. 4. Torque the new tailgate striker to 30 lb-ft +/- 4 lb-ft (40 N.m +/- 6 N.m). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072502A 2004-2008 F-150, F-Super 0.2 Hr. Duty, 2006-2008 Mark LT and 2004-2005 and 2007-2008 Explorer Sport Trac: Replace One Tailgate Striker, Includes Time To Align Tailgate (Do Not Use With 40442A) 072502B 2004-2008 F-150, F-Super 0.3 Hr. Duty, 2006-2008 Mark LT and 2004-2005 and 2007-2008 Explorer Sport Trac: Replace Both Tailgate Strikers, Includes Time To Align Tailgate (Do Not Use With 40442A) DEALER CODING Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-25-2 > Dec > 07 > Body - Rattle Noise From Tailgate > Page 8264 CONDITION BASIC PART NO. CODE 99404A42 30 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate Striker: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures Heater Hose: All Technical Service Bulletins A/C - Compressor Shuts OFF in High Temperatures TSB 07-24-7 12/10/07 A/C COMPRESSOR SHUTOFF - HIGH AMBIENT TEMPERATURES - VEHICLE STATIONARY IN GEAR FORD: 2007-2008 F-150, F-150 LINCOLN: 2007-2008 Mark LT ISSUE Some 2007-2008 Mark LT and F-150 vehicles equipped with 5.4L or 4.6L engine only, may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C), when the vehicle is stationary for periods longer than 15 minutes, with the transmission in gear. Idling in gear and extreme ambient temperatures may cause the vehicle control systems to disable A/C compressor operation. ACTION Follow the Service Procedure steps to replace the A/C compressor pulley and coolant pump pulley. SERVICE PROCEDURE NOTE THIS TSB IS INTENDED TO RESTORE A/C COMPRESSOR OPERATION IN EXTREME HIGH AMBIENT TEMPERATURES WHEN THE TRANSMISSION IS PLACED IN THE PARK POSITION. DO NOT ATTEMPT TO ADDRESS CUSTOMER CONCERNS OF GENERAL A/C TEMPERATURE OUTPUT PERFORMANCE WITH THIS TSB. THIS TSB WILL NOT IMPROVE A/C SYSTEM DUCT TEMPERATURE OUTPUT PERFORMANCE. NOTE DURING EXTREME HIGH AMBIENT TEMPERATURES WHEN IDLING STATIONARY FOR EXTENDED PERIODS OF TIME IN GEAR, IT IS RECOMMENDED TO OPERATE THE A/C IN THE MAX POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, AND PUT THE TRANSMISSION INTO THE PARK POSITION TO CONTINUE TO RECEIVE COOL AIR FROM THE A/C SYSTEM. 1. Replace the A/C compressor pulley. Follow Workshop Manual (WSM), Section 412-01 for removal and installation details. 2. Replace the coolant pump pulley. Follow WSM, Section 303-03 for removal and installation details. 3. Drain approximately 1 quart of coolant from the cooling system into a clean container which will permit reuse of coolant in the vehicle. Refer to WSM, Section 303-03. 4. Replace the clamp on the heater core feed hose, near the right hand front of engine, at the water pump outlet pipe connection point. 5. Refill the cooling system. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072407A 2007-2008 F-150 4X2, 1.7 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X2. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate Striker: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures > Page 8270 8509A,8620F, 8616A, 18472A). 072407B 2007-2008 F-150 4X4, 1.9 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X4. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, 8509A,8620F, 8616A, 18472A). DEALER CODING CONDITION BASIC PART NO. CODE 8A616 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate Striker: > 07-24-7 > Dec > 07 > A/C - Compressor Shuts OFF in High Temperatures > Page 8276 8509A,8620F, 8616A, 18472A). 072407B 2007-2008 F-150 4X4, 1.9 Hrs. 5.4L and 4.6L Engines, 2007-2008 Mark LT 4X4. Replace A/C Compressor Pulley, Coolant Pump Pulley and Heater Feed Hose Clamp at Coolant Pump Outlet. Includes lime Remove and Install A/C Compressor and to Drain and Fill Cooling system.(Do Not Use With 19700A, 19700A4, 8509A,8620F, 8616A, 18472A). DEALER CODING CONDITION BASIC PART NO. CODE 8A616 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Specifications Torque Specifications Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Specifications > Page 8280 Truck Bed: Description and Operation PICKUP BED The pickup bed consists of: - styleside pickup bed (pan assembly). - pickup box tie-down hooks. - flareside pickup bed (pan assembly). - body side wheel opening splash shield. - flareside body side outer panel. - rear-wheel opening moulding (four wheel drive [4WD] only). The styleside pickup bed: - is standard. - comes in standard lengths of 1.67 m (5.5 ft) or 1.98 m (6.5 ft) or optional 2.43 m (8 ft) length. - is double-wall steel construction. - houses 4 stake pockets in the top of the 1.98 m (6.5 ft) bed and 6 stake pockets on the 2.43 m (8 ft) bed. - on 4WD vehicles, includes rear-wheel opening mouldings. - is constructed of an inner steel box and steel tailgate with moulded outer panels. The flareside pickup bed: - is optional on both rear wheel drive (RWD) and 4WD models in 1.98 m (6.5 ft) length only. - has integrated step pads on each side of the flared wheel openings. Both styleside and flareside pickup beds: - come standard with 4 pickup bed tie-down hooks. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Specifications > Page 8281 Truck Bed: Service and Repair PICKUP BED Removal and Installation 1. Remove the ground bolt. - To install, tighten to 10 Nm (89 lb-in). 2. Disconnect the main tail lamp connector and reverse parking aid, if equipped. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Specifications > Page 8282 3. Disconnect the license lamp connectors. 4. If equipped, disconnect the trailer harness connector(s) from the rear bumper. 5. Remove the fuel filler tube-to-pickup bed clamp. - To install, tighten to 7 Nm (62 lb-in). 6. Remove the 3 fuel filler neck screws. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Truck Bed > Component Information > Specifications > Page 8283 7. CAUTION: Remove the fuel fill door assembly. Otherwise, damage to the fuel fill tube and fuel door assembly may occur when the pickup bed is removed. Remove the fuel door assembly. Press in the 2 retaining tabs on top of the fuel door assembly. - Slide the fuel door assembly out of the pickup bed. 8. NOTE: - The pickup bed bolts are one time use only. Install new bolts whenever the bolts are removed. - All 8-foot pickup beds have 8 bolts; all others have 6 bolts. Remove and discard the 8 pickup box bolts. To install, tighten to 80 Nm (59 lb-ft). 9. CAUTION: To avoid damaging the fuel fill tube, guide the fuel fill tube out of the fuel door opening as the pickup bed is removed. Remove the pickup box. Guide the fuel fill tube out of the fuel door opening. 10. NOTE: New attachment clips must be installed whenever the pickup box is removed. All 8-foot beds will have 8 attachment clips. All other beds will have 6 attachment clips. Install new attachment clips before reinstalling the pickup box. 11. NOTE: Install a new fuel filler tube clamp if specified torque is not obtained or if part strips during reinstallation. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 08-25-5 > Dec > 08 > Body - L/H Cowl Panel Popped Up Cowl Moulding / Trim: Customer Interest Body - L/H Cowl Panel Popped Up TSB 08-25-5 12/22/08 DRIVERS SIDE COWL PANEL POPPED-UP FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 07-24-5 to update the Service Procedure. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT (Excluding Heritage) vehicles may encounter a concern of the windshield cowl panel not being fully seated, popped up or giving the appearance of being warped. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE HEAVY-PRESSURE MAY RESULT IN BREAKING OF THE J-HOOK. 1. Attempt to seat the cowl panel by gently applying pressure, first downward, then rearward to the inboard rear area of the cowl panel, forward of the windshield to determine if it will engage the sheet metal flange below. (Figure 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 08-25-5 > Dec > 08 > Body - L/H Cowl Panel Popped Up > Page 8294 2. Pull test will confirm if the hooks are engaged and that the sheet metal flange has not been bent too far forward. From the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. (Figure 2) 1. Remove the cowl panel(s). Refer to Workshop Manual (WSM), Section 501-02 for removal instructions. 2. Confirm engagement and proper installation of cowl grill. The cowl design makes use of long J-hooks (Figure 2, view A) on the bottom side of the cowl panel to engage a sheet metal flange below the cowl panel sur[ace area. On vehicles built prior to August 2006, you will need to visually confirm that the J-hooks on the right hand (RH) parts are engaged to the sheet metal flange. The left hand (LH) part will need to be removed to observe this. Vehicles built after August 2006 have a raised feature forward of the screw attachment support tower on the RH part (near the center line of the vehicle), which is to ensure that the cowl panel is not built forward and is in the correct position for the J-hooks to engage the sheet metal flange. Check if the LH cowl panel is installed correctly, you can either tug the part forward or outward (towards the fender). Each move should cause the rear of the part or the split joint between the RH and LH cowl grills to pop up if the J-hooks were not engaged. Relying on an audible confirmation of engagement could cause a false-positive assessment of the parts being installed and retaining correctly and should not be used as the final indicator of correct installation. 3. If the RH part does not have the split joint hook engaged to the sheet metal flange it must be set properly before the LH part can be corrected. Remove LH cowl grill and set aside. Loosen screw on RH cowl grill. Push down and rearward over the hook to engage the sheet metal flange. While holding part rearward, re-tighten the screw. 4. If it is found that the LH parts cannot be installed correctly (the rear edge or split joint pops up after panel is shifted), remove the LH cowl panel (driver side) and place it out of the way. The flange to which the J-hook engages needs to be adjusted slightly upward 3/32" (2 mm) in two areas using a pair of wide bill pliers (Figure 1, view B). Then install the cowl panel and retest by trying to shift either forward or outward. An audible click confirmation of hook engagement could cause a false positive assessment of the parts being installed correctly and should not be used as the final indicator of correct installation. Using the pull test, from the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 08-25-5 > Dec > 08 > Body - L/H Cowl Panel Popped Up > Page 8295 pulled outboard if the hooks are not properly engaged to the flange. This will confirm the flange has not been bent too far forward. If the rear edge and split joint stays down and the margin on the inboard edge to the LH part is consistent, then complete installation of the LH cowl has been achieved. (Figure 3) WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082505A 2004-2008 F-150, 0.3 Hr. 2006-2008 Mark LT: Attempt To Seat Cowl Panel, Includes Time To Adjust Flange If Necessary (Do Not Use With 17508A 17526A, 17528A) DEALER CODING CONDITION BASIC PART NO. CODE 7002010 07 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 08-25-5 > Dec > 08 > Body - L/H Cowl Panel Popped Up Cowl Moulding / Trim: All Technical Service Bulletins Body - L/H Cowl Panel Popped Up TSB 08-25-5 12/22/08 DRIVERS SIDE COWL PANEL POPPED-UP FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 07-24-5 to update the Service Procedure. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT (Excluding Heritage) vehicles may encounter a concern of the windshield cowl panel not being fully seated, popped up or giving the appearance of being warped. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE HEAVY-PRESSURE MAY RESULT IN BREAKING OF THE J-HOOK. 1. Attempt to seat the cowl panel by gently applying pressure, first downward, then rearward to the inboard rear area of the cowl panel, forward of the windshield to determine if it will engage the sheet metal flange below. (Figure 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 08-25-5 > Dec > 08 > Body - L/H Cowl Panel Popped Up > Page 8301 2. Pull test will confirm if the hooks are engaged and that the sheet metal flange has not been bent too far forward. From the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. (Figure 2) 1. Remove the cowl panel(s). Refer to Workshop Manual (WSM), Section 501-02 for removal instructions. 2. Confirm engagement and proper installation of cowl grill. The cowl design makes use of long J-hooks (Figure 2, view A) on the bottom side of the cowl panel to engage a sheet metal flange below the cowl panel sur[ace area. On vehicles built prior to August 2006, you will need to visually confirm that the J-hooks on the right hand (RH) parts are engaged to the sheet metal flange. The left hand (LH) part will need to be removed to observe this. Vehicles built after August 2006 have a raised feature forward of the screw attachment support tower on the RH part (near the center line of the vehicle), which is to ensure that the cowl panel is not built forward and is in the correct position for the J-hooks to engage the sheet metal flange. Check if the LH cowl panel is installed correctly, you can either tug the part forward or outward (towards the fender). Each move should cause the rear of the part or the split joint between the RH and LH cowl grills to pop up if the J-hooks were not engaged. Relying on an audible confirmation of engagement could cause a false-positive assessment of the parts being installed and retaining correctly and should not be used as the final indicator of correct installation. 3. If the RH part does not have the split joint hook engaged to the sheet metal flange it must be set properly before the LH part can be corrected. Remove LH cowl grill and set aside. Loosen screw on RH cowl grill. Push down and rearward over the hook to engage the sheet metal flange. While holding part rearward, re-tighten the screw. 4. If it is found that the LH parts cannot be installed correctly (the rear edge or split joint pops up after panel is shifted), remove the LH cowl panel (driver side) and place it out of the way. The flange to which the J-hook engages needs to be adjusted slightly upward 3/32" (2 mm) in two areas using a pair of wide bill pliers (Figure 1, view B). Then install the cowl panel and retest by trying to shift either forward or outward. An audible click confirmation of hook engagement could cause a false positive assessment of the parts being installed correctly and should not be used as the final indicator of correct installation. Using the pull test, from the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 08-25-5 > Dec > 08 > Body - L/H Cowl Panel Popped Up > Page 8302 pulled outboard if the hooks are not properly engaged to the flange. This will confirm the flange has not been bent too far forward. If the rear edge and split joint stays down and the margin on the inboard edge to the LH part is consistent, then complete installation of the LH cowl has been achieved. (Figure 3) WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082505A 2004-2008 F-150, 0.3 Hr. 2006-2008 Mark LT: Attempt To Seat Cowl Panel, Includes Time To Adjust Flange If Necessary (Do Not Use With 17508A 17526A, 17528A) DEALER CODING CONDITION BASIC PART NO. CODE 7002010 07 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 8303 Cowl Moulding / Trim: By Symptom Technical Service Bulletin # 08-25-5 Date: 081222 Body - L/H Cowl Panel Popped Up TSB 08-25-5 12/22/08 DRIVERS SIDE COWL PANEL POPPED-UP FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 07-24-5 to update the Service Procedure. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT (Excluding Heritage) vehicles may encounter a concern of the windshield cowl panel not being fully seated, popped up or giving the appearance of being warped. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE HEAVY-PRESSURE MAY RESULT IN BREAKING OF THE J-HOOK. 1. Attempt to seat the cowl panel by gently applying pressure, first downward, then rearward to the inboard rear area of the cowl panel, forward of the windshield to determine if it will engage the sheet metal flange below. (Figure 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 8304 2. Pull test will confirm if the hooks are engaged and that the sheet metal flange has not been bent too far forward. From the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. (Figure 2) 1. Remove the cowl panel(s). Refer to Workshop Manual (WSM), Section 501-02 for removal instructions. 2. Confirm engagement and proper installation of cowl grill. The cowl design makes use of long J-hooks (Figure 2, view A) on the bottom side of the cowl panel to engage a sheet metal flange below the cowl panel sur[ace area. On vehicles built prior to August 2006, you will need to visually confirm that the J-hooks on the right hand (RH) parts are engaged to the sheet metal flange. The left hand (LH) part will need to be removed to observe this. Vehicles built after August 2006 have a raised feature forward of the screw attachment support tower on the RH part (near the center line of the vehicle), which is to ensure that the cowl panel is not built forward and is in the correct position for the J-hooks to engage the sheet metal flange. Check if the LH cowl panel is installed correctly, you can either tug the part forward or outward (towards the fender). Each move should cause the rear of the part or the split joint between the RH and LH cowl grills to pop up if the J-hooks were not engaged. Relying on an audible confirmation of engagement could cause a false-positive assessment of the parts being installed and retaining correctly and should not be used as the final indicator of correct installation. 3. If the RH part does not have the split joint hook engaged to the sheet metal flange it must be set properly before the LH part can be corrected. Remove LH cowl grill and set aside. Loosen screw on RH cowl grill. Push down and rearward over the hook to engage the sheet metal flange. While holding part rearward, re-tighten the screw. 4. If it is found that the LH parts cannot be installed correctly (the rear edge or split joint pops up after panel is shifted), remove the LH cowl panel (driver side) and place it out of the way. The flange to which the J-hook engages needs to be adjusted slightly upward 3/32" (2 mm) in two areas using a pair of wide bill pliers (Figure 1, view B). Then install the cowl panel and retest by trying to shift either forward or outward. An audible click confirmation of hook engagement could cause a false positive assessment of the parts being installed correctly and should not be used as the final indicator of correct installation. Using the pull test, from the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 8305 pulled outboard if the hooks are not properly engaged to the flange. This will confirm the flange has not been bent too far forward. If the rear edge and split joint stays down and the margin on the inboard edge to the LH part is consistent, then complete installation of the LH cowl has been achieved. (Figure 3) WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082505A 2004-2008 F-150, 0.3 Hr. 2006-2008 Mark LT: Attempt To Seat Cowl Panel, Includes Time To Adjust Flange If Necessary (Do Not Use With 17508A 17526A, 17528A) DEALER CODING CONDITION BASIC PART NO. CODE 7002010 07 Disclaimer Technical Service Bulletin # 08-25-5 Date: 081222 Body - L/H Cowl Panel Popped Up TSB 08-25-5 12/22/08 DRIVERS SIDE COWL PANEL POPPED-UP FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT This article supersedes TSB 07-24-5 to update the Service Procedure. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT (Excluding Heritage) vehicles may encounter a concern of the windshield cowl panel not being fully seated, popped up or giving the appearance of being warped. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE HEAVY-PRESSURE MAY RESULT IN BREAKING OF THE J-HOOK. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 8306 1. Attempt to seat the cowl panel by gently applying pressure, first downward, then rearward to the inboard rear area of the cowl panel, forward of the windshield to determine if it will engage the sheet metal flange below. (Figure 1) 2. Pull test will confirm if the hooks are engaged and that the sheet metal flange has not been bent too far forward. From the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. (Figure 2) 1. Remove the cowl panel(s). Refer to Workshop Manual (WSM), Section 501-02 for removal instructions. 2. Confirm engagement and proper installation of cowl grill. The cowl design makes use of long J-hooks (Figure 2, view A) on the bottom side of the cowl panel to engage a sheet metal flange below the cowl panel sur[ace area. On vehicles built prior to August 2006, you will need to visually confirm that the J-hooks on the right hand (RH) parts are engaged to the sheet metal flange. The left hand (LH) part will need to be removed to observe this. Vehicles built after August 2006 have a raised feature forward of the screw attachment support tower on the RH part (near the center line of the vehicle), which is to ensure that the cowl panel is not built forward and is in the correct position for the J-hooks to engage the sheet metal flange. Check if the LH cowl panel is installed correctly, you can either tug the part forward or outward (towards the fender). Each move should cause the rear of the part or the split joint between the RH and LH cowl grills to pop up if the J-hooks were not engaged. Relying on an audible confirmation of engagement could cause a false-positive assessment of the parts being installed and retaining correctly and should not be used as the final indicator of correct installation. 3. If the RH part does not have the split joint hook engaged to the sheet metal flange it must be set properly before the LH part can be corrected. Remove LH cowl grill and set aside. Loosen screw on RH cowl grill. Push down and rearward over the hook to engage the sheet metal flange. While holding part rearward, re-tighten the screw. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 8307 4. If it is found that the LH parts cannot be installed correctly (the rear edge or split joint pops up after panel is shifted), remove the LH cowl panel (driver side) and place it out of the way. The flange to which the J-hook engages needs to be adjusted slightly upward 3/32" (2 mm) in two areas using a pair of wide bill pliers (Figure 1, view B). Then install the cowl panel and retest by trying to shift either forward or outward. An audible click confirmation of hook engagement could cause a false positive assessment of the parts being installed correctly and should not be used as the final indicator of correct installation. Using the pull test, from the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. This will confirm the flange has not been bent too far forward. If the rear edge and split joint stays down and the margin on the inboard edge to the LH part is consistent, then complete installation of the LH cowl has been achieved. (Figure 3) WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082505A 2004-2008 F-150, 0.3 Hr. 2006-2008 Mark LT: Attempt To Seat Cowl Panel, Includes Time To Adjust Flange If Necessary (Do Not Use With 17508A 17526A, 17528A) DEALER CODING CONDITION BASIC PART NO. CODE 7002010 07 Disclaimer Technical Service Bulletin # 08-25-5 Date: 081222 Body - L/H Cowl Panel Popped Up TSB 08-25-5 12/22/08 DRIVERS SIDE COWL PANEL POPPED-UP FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 8308 This article supersedes TSB 07-24-5 to update the Service Procedure. ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT (Excluding Heritage) vehicles may encounter a concern of the windshield cowl panel not being fully seated, popped up or giving the appearance of being warped. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE HEAVY-PRESSURE MAY RESULT IN BREAKING OF THE J-HOOK. 1. Attempt to seat the cowl panel by gently applying pressure, first downward, then rearward to the inboard rear area of the cowl panel, forward of the windshield to determine if it will engage the sheet metal flange below. (Figure 1) 2. Pull test will confirm if the hooks are engaged and that the sheet metal flange has not been bent too far forward. From the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. (Figure 2) 1. Remove the cowl panel(s). Refer to Workshop Manual (WSM), Section 501-02 for removal instructions. 2. Confirm engagement and proper installation of cowl grill. The cowl design makes use of long J-hooks (Figure 2, view A) on the bottom side of the cowl panel to engage a sheet metal flange below the cowl panel sur[ace area. On vehicles built prior to August 2006, you will need to visually Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 8309 confirm that the J-hooks on the right hand (RH) parts are engaged to the sheet metal flange. The left hand (LH) part will need to be removed to observe this. Vehicles built after August 2006 have a raised feature forward of the screw attachment support tower on the RH part (near the center line of the vehicle), which is to ensure that the cowl panel is not built forward and is in the correct position for the J-hooks to engage the sheet metal flange. Check if the LH cowl panel is installed correctly, you can either tug the part forward or outward (towards the fender). Each move should cause the rear of the part or the split joint between the RH and LH cowl grills to pop up if the J-hooks were not engaged. Relying on an audible confirmation of engagement could cause a false-positive assessment of the parts being installed and retaining correctly and should not be used as the final indicator of correct installation. 3. If the RH part does not have the split joint hook engaged to the sheet metal flange it must be set properly before the LH part can be corrected. Remove LH cowl grill and set aside. Loosen screw on RH cowl grill. Push down and rearward over the hook to engage the sheet metal flange. While holding part rearward, re-tighten the screw. 4. If it is found that the LH parts cannot be installed correctly (the rear edge or split joint pops up after panel is shifted), remove the LH cowl panel (driver side) and place it out of the way. The flange to which the J-hook engages needs to be adjusted slightly upward 3/32" (2 mm) in two areas using a pair of wide bill pliers (Figure 1, view B). Then install the cowl panel and retest by trying to shift either forward or outward. An audible click confirmation of hook engagement could cause a false positive assessment of the parts being installed correctly and should not be used as the final indicator of correct installation. Using the pull test, from the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. This will confirm the flange has not been bent too far forward. If the rear edge and split joint stays down and the margin on the inboard edge to the LH part is consistent, then complete installation of the LH cowl has been achieved. (Figure 3) WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082505A 2004-2008 F-150, 0.3 Hr. 2006-2008 Mark LT: Attempt To Seat Cowl Panel, Includes Time To Adjust Flange If Necessary (Do Not Use With 17508A 17526A, 17528A) DEALER CODING CONDITION BASIC PART NO. CODE 7002010 07 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair DOOR GLASS TOP RUN - FRONT Exploded View Removal and Installation 1. Remove the front door trim panel. 2. Remove the front door window glass. 3. Remove the front door glass top run. - Remove the front door glass top run through the top opening of the front door. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear, SuperCab Rear Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Rear, SuperCab DOOR GLASS TOP RUN - REAR, SUPERCAB Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear, SuperCab > Page 8318 SuperCrew Removal and Installation 1. Position the rear door window glass in the full DOWNWARD position. 2. Remove the rear door trim panel. 3. Remove the rear door mounted speaker. 4. Remove the rear door interior moulding. 5. Remove the rear door window glass top run. - Remove the rear door window glass top run through the top opening of the rear door. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear, SuperCab > Page 8319 Rear Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Rear, SuperCrew DOOR GLASS TOP RUN - REAR, SUPERCREW Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear, SuperCab > Page 8320 SuperCrew Removal and Installation 1. Position the rear door window glass in the full DOWNWARD position. 2. Remove the rear door trim panel. 3. Remove the rear door mounted speaker. 4. Remove the rear door interior moulding. 5. Remove the rear door window glass top run. - Remove the rear door window glass top run through the top opening of the rear door. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body Sunroof Water Leaks During High Pressure Car Wash Sunroof / Moonroof Weatherstrip: Customer Interest Body - Sunroof Water Leaks During High Pressure Car Wash TSB 08-24-8 12/08/08 WATER LEAKS - ROOF OPENING PANEL DURING HIGH PRESSURE CAR WASH FORD: 2005-2008 F-150, F-250, F-350, F-450, F-550 2005-2009 Expedition LINCOLN: 2005-2009 Navigator 2006-2008 Mark LT This article supersedes TSB 08-1-4 to update the Part List and Service procedure. ISSUE Some 2005-2009 Expedition, Navigator, 2005-2008 F-150, F-Super Duty and 2006-2008 Mark LT vehicles with factory installed roof opening panel may experience a water leak at the rear of roof opening panel during a high pressure car wash. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2005-2008 F-150 / F-Super Duty 250-550 / 2006-2008 Mark LT 1. Remove roof opening panel glass only. Refer to Work Shop Manual (WSM), Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. With rear trough removed; wipe clean the top inside of the trough with an alcohol based cleaner or equivalent. 5. Remove the adhesive tape covering from trough seal. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body Sunroof Water Leaks During High Pressure Car Wash > Page 8329 6. Attach seal to front of trough starting at one end of the trough. Make sure the vertical leg of seal lines up against front flange of trough. (Figures 1-3) 7. Secure seal across entire trough. Apply pressure along entire seal to ensure bonding to trough. 8. Install the rear trough onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 9. Remove protective covering. 10. Install roof opening panel following WSM, Section 501-17. 2005-2009 Expedition / Navigator 1. Remove roof opening panel glass only. Refer to WSM, Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. Install new trough and seal assembly. 5. Install the rear trough and seal assembly onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 6. Remove protective covering. 7. Install roof opening panel following WSM, Section 501-17. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body Sunroof Water Leaks During High Pressure Car Wash > Page 8330 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082408A 2005-2009 Expedition, 0.5 Hr. Navigator: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) 082408A 2005-2008 F-Super Duty, 0.6 Hr. F-150, 2005-2008 Mark LT: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) DEALER CODING CONDITION BASIC PART NO. CODE 78502C50 07 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Sunroof Water Leaks During High Pressure Car Wash TSB 08-24-8 12/08/08 WATER LEAKS - ROOF OPENING PANEL DURING HIGH PRESSURE CAR WASH FORD: 2005-2008 F-150, F-250, F-350, F-450, F-550 2005-2009 Expedition LINCOLN: 2005-2009 Navigator 2006-2008 Mark LT This article supersedes TSB 08-1-4 to update the Part List and Service procedure. ISSUE Some 2005-2009 Expedition, Navigator, 2005-2008 F-150, F-Super Duty and 2006-2008 Mark LT vehicles with factory installed roof opening panel may experience a water leak at the rear of roof opening panel during a high pressure car wash. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2005-2008 F-150 / F-Super Duty 250-550 / 2006-2008 Mark LT 1. Remove roof opening panel glass only. Refer to Work Shop Manual (WSM), Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. With rear trough removed; wipe clean the top inside of the trough with an alcohol based cleaner or equivalent. 5. Remove the adhesive tape covering from trough seal. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 8336 6. Attach seal to front of trough starting at one end of the trough. Make sure the vertical leg of seal lines up against front flange of trough. (Figures 1-3) 7. Secure seal across entire trough. Apply pressure along entire seal to ensure bonding to trough. 8. Install the rear trough onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 9. Remove protective covering. 10. Install roof opening panel following WSM, Section 501-17. 2005-2009 Expedition / Navigator 1. Remove roof opening panel glass only. Refer to WSM, Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. Install new trough and seal assembly. 5. Install the rear trough and seal assembly onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 6. Remove protective covering. 7. Install roof opening panel following WSM, Section 501-17. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 8337 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082408A 2005-2009 Expedition, 0.5 Hr. Navigator: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) 082408A 2005-2008 F-Super Duty, 0.6 Hr. F-150, 2005-2008 Mark LT: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) DEALER CODING CONDITION BASIC PART NO. CODE 78502C50 07 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 8343 View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch C277 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 8346 C278 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 8347 Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Brake Pedal Switch (BPS)/Brake Deactivator Switch The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is not applied. When the brake pedal is applied, the normally closed switch opens and power is removed from the PCM. On some applications the normally closed BPS, along with the normally open BPP switch, are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not changing states when they were expected to, a diagnostic trouble code (DTC) is set by the PCM strategy. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 8348 Brake Switch (Cruise Control): Service and Repair SPEED CONTROL DEACTIVATOR SWITCH Removal and Installation 1. CAUTION: Do not press the brake pedal when removing or installing the speed control deactivator switch or damage to the switch will occur. Disconnect the speed control deactivator switch electrical connector. 2. Rotate the speed control deactivator switch counterclockwise 45 degrees and remove it. 3. NOTE: The speed control deactivator switch is self-adjusting. Do not press the brake pedal during installation. Initial installation of the speed control deactivator switch allows for one adjustment. If additional adjustments are necessary, install a new speed control deactivator switch. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 8352 C257 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 8353 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations View 151-20 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Without Remote Audio/Climate Controls Cruise Control Switch: Service and Repair Speed Control Switch - Without Remote Audio/Climate Controls SPEED CONTROL SWITCH - WITHOUT REMOTE AUDIO/CLIMATE CONTROLS Removal and Installation 1. Remove the steering wheel. 2. Remove the steering wheel base cover. 3. Disconnect the speed control switches electrical connectors. 4. Remove the 4 nuts and the speed control switches. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Without Remote Audio/Climate Controls > Page 8359 Cruise Control Switch: Service and Repair Speed Control Switch - With Remote Audio/Climate Controls SPEED CONTROL SWITCH - WITH REMOTE AUDIO/CLIMATE CONTROLS Removal and Installation 1. Remove the steering wheel. 2. Remove the steering wheel base cover. 3. Disconnect the speed control switch electrical connector. 4. Remove the 2 nuts and the speed control switch. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 8365 View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch C277 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 8368 C278 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 8369 Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Brake Pedal Switch (BPS)/Brake Deactivator Switch The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is not applied. When the brake pedal is applied, the normally closed switch opens and power is removed from the PCM. On some applications the normally closed BPS, along with the normally open BPP switch, are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not changing states when they were expected to, a diagnostic trouble code (DTC) is set by the PCM strategy. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 8370 Brake Switch (Cruise Control): Service and Repair SPEED CONTROL DEACTIVATOR SWITCH Removal and Installation 1. CAUTION: Do not press the brake pedal when removing or installing the speed control deactivator switch or damage to the switch will occur. Disconnect the speed control deactivator switch electrical connector. 2. Rotate the speed control deactivator switch counterclockwise 45 degrees and remove it. 3. NOTE: The speed control deactivator switch is self-adjusting. Do not press the brake pedal during installation. Initial installation of the speed control deactivator switch allows for one adjustment. If additional adjustments are necessary, install a new speed control deactivator switch. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 8374 C257 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 8375 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations View 151-20 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Without Remote Audio/Climate Controls Cruise Control Switch: Service and Repair Speed Control Switch - Without Remote Audio/Climate Controls SPEED CONTROL SWITCH - WITHOUT REMOTE AUDIO/CLIMATE CONTROLS Removal and Installation 1. Remove the steering wheel. 2. Remove the steering wheel base cover. 3. Disconnect the speed control switches electrical connectors. 4. Remove the 4 nuts and the speed control switches. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Without Remote Audio/Climate Controls > Page 8381 Cruise Control Switch: Service and Repair Speed Control Switch - With Remote Audio/Climate Controls SPEED CONTROL SWITCH - WITH REMOTE AUDIO/CLIMATE CONTROLS Removal and Installation 1. Remove the steering wheel. 2. Remove the steering wheel base cover. 3. Disconnect the speed control switch electrical connector. 4. Remove the 2 nuts and the speed control switch. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component Information > Diagrams C2286 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component Information > Diagrams > Page 8386 Air Bag Deactivation Indicator: Service and Repair PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR Passenger Air Bag Deactivation (PAD) Indicator Removal and Installation NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Depower the SRS. 2. Remove the instrument panel center finish panel. 3. Disconnect the passenger air bag deactivation (PAD) indicator electrical connector. 4. Remove the PAD indicator screws and PAD indicator. 5. To install, reverse the removal procedure. 6. Repower the SRS. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8391 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8392 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8393 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8394 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8395 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8396 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8397 Audible Warning Device: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8398 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8399 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8400 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8401 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8402 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8403 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8404 Audible Warning Device: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 66-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8405 66-2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8406 66-3 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8411 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8412 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8413 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8414 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8415 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8416 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8417 Cigarette Lighter: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8418 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8419 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8420 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8421 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8422 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8423 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8424 C2031 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8425 Cigarette Lighter: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 44-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8426 44-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams C909 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Vehicle Demagnetizing Compass: Service and Repair Vehicle Demagnetizing VEHICLE DEMAGNETIZING CAUTION: During demagnetizing, the demagnetizer coil is pulled toward the vehicle. Place a cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth covers the front third and the entire width of the roof. NOTE: - The demagnetizing process requires the use of a demagnetizing coil commonly used by television repair technicians to demagnetize television tubes. - To demagnetize, use a constant circular motion over the vehicle roof. Do not turn off the demagnetizer while sweeping the vehicle roof to prevent remagnetizing ferrous materials contained in the vehicle. - During the demagnetizing process, make sure the phenolic surface of the tool (the side opposite the handle) is closest to the vehicle surface. 1. Demagnetize the front third of the vehicle roof. 1 Turn on the demagnetizer at least 1 m (3 ft) away from the vehicle. 2 Holding the demagnetizer no more than 2.5 cm (1 inch) from the vehicle roof and starting on the passenger side, demagnetize the front third of the vehicle roof closest to the windshield using a constant circular motion. Keep the circle radius within 30 cm (12 inches) while sweeping across the entire surface of the vehicle roof closest to the windshield. Continue the circular motion 4 times. 3 After the fourth pass and without stopping, move the demagnetizer at least 1 m (3 ft) away from the vehicle. 4 Turn the demagnetizer off. 2. Carry out the compass zone adjustment procedure. Refer to Compass Zone Adjustment. See: Compass Zone Adjustment 3. Carry out the compass calibration adjustment procedure. Refer to Compass Calibration. See: Compass Calibration Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Vehicle Demagnetizing > Page 8432 Compass: Service and Repair Compass Zone Adjustment With Message Center COMPASS ZONE ADJUSTMENT With Message Center 1. NOTE: The compass zone setting is preset from the factory to Zone 8. Determine which magnetic zone you are in for your geographic location. 2. Locate the compass module at the base of the mirror. 3. Turn the ignition key to the ON position. 4. NOTE: To exit the compass zone adjustment before carrying out the compass zone adjustment procedure, press the INFO button on the message center switch. Press and hold the reset button on the LH top of the compass module until RESET FOR ZONE and the current setting (1-15) appears in the message center display. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Vehicle Demagnetizing > Page 8433 5. Press the SETUP button on the message center switch repeatedly until the correct geographic location for your area is displayed in the message center. 6. Press the RESET button to exit the zone setting procedure and to lock your selected zone setting. The message center displays CALIBRATION COMPLETE. Without Message Center COMPASS ZONE ADJUSTMENT Without Message Center 1. NOTE: The compass zone setting is preset from the factory to Zone 8. Determine which magnetic zone you are in for your geographic location. 2. Locate the compass module at the base of the mirror. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Vehicle Demagnetizing > Page 8434 3. Turn the ignition key to the ON position. 4. Press and hold the reset button on the LH top of the compass module until the current setting (1-15) area appears in the instrument cluster integrated display. 5. Press the reset button repeatedly to cycle through the zone settings until the correct setting for your geographic location is displayed. 6. Release pressure on the reset button to exit the zone setting mode. After approximately 5 seconds the display reports the direction and the zone is set. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Vehicle Demagnetizing > Page 8435 Compass: Service and Repair Compass Calibration With Message Center COMPASS CALIBRATION With Message Center 1. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or structures. Switch off all non-essential electrical accessories (rear window defrost, heater A/C, map lamps, wipers, etc.) and make sure all doors are closed. Start the vehicle. 2. Locate the compass module at the base of the mirror. 3. NOTE: To exit the calibration adjustment mode before carrying out a compass adjustment, press the INFO button. Press and hold the reset button on the LH top of the compass module until RESET FOR ZONE appears in the message center display. 4. NOTE: The message center display advances automatically to display the CIRCLE SLOWLY TO CALIBRATE message. Slowly drive the vehicle in a circle no more than 5 times at no more than 5 km/h (3 mph) until CIRCLE SLOWLY TO CAL changes to CALIBRATION COMPLETED in the message center. Without Message Center COMPASS CALIBRATION Without Message Center 1. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or structures. Switch off all non-essential electrical accessories (rear window defrost, heater A/C, map lamps, wipers, etc.) and make sure all doors are closed. Start the vehicle. 2. Locate the compass module at the base of the mirror. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Vehicle Demagnetizing > Page 8436 3. NOTE: To exit the CAL mode before carrying out a compass adjustment, turn the ignition switch to the OFF position. Press and hold the reset button located on the LH top of the compass sensor module until ZONE is displayed in the instrument cluster integrated circuit display. Continue to hold the button down until CAL is displayed and release the button. 4. NOTE: If the CIRCLE SLOWLY display does not turn off after the vehicle is driven in a circle no more than 5 times, demagnetize the vehicle and repeat the procedure. Slowly drive the vehicle in a circle no more than 5 times at no more than 5 km/h (3 mph) until CAL turns off. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) Depowering Procedure WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, remove the trim panel, the cover and the RCM fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install the RCM fuse 19 (10A) to the CJB and install the cover and trim panel. 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8442 4. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8443 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, remove the trim panel, the cover, and the RCM fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Remove the driver air bag module. 8. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8444 9. While pushing in on the 2 glove compartment door tabs, position the glove compartment downward. 10. Through the glove compartment opening, release the tabs and disconnect the LH passenger air bag module electrical connector. 11. Attach the restraint system diagnostic tool to the vehicle harness side of the LH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8445 12. Through the glove compartment opening, release the tabs and disconnect the RH passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the RH passenger air bag module electrical connector. 14. Install the RCM fuse 19 (10A) to the CJB. 15. Connect the battery ground cable. Reactivation 1. Remove the RCM fuse 19 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the RH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8446 4. Through the glove compartment opening, connect the RH passenger air bag module electrical connector. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the LH passenger air bag module electrical connector. 6. Through the glove compartment opening, connect the LH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8447 7. Close the glove compartment. 8. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 9. Turn the ignition switch from OFF to ON. 10. Install the RCM fuse 19 (10A) to the CJB and install the cover and trim panel. 11. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 12. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Left Front View 151-30 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Left Front > Page 8452 View 151-31 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Left Front > Page 8453 View 151-33 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front C526 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8456 C602 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8457 C715 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8458 C820 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 8459 Door Switch: Service and Repair DOOR AJAR SWITCH Removal and Installation 1. Remove the front or rear door latch. 2. Release the locking tab and remove the door ajar switch. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 8463 C253 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 8464 Driver/Vehicle Information Display: Description and Operation INFORMATION AND MESSAGE CENTER Message Center The message center is a fixed format display that is controlled by the message center switches. The message center is located in the lower RH corner of the instrument cluster and displays important vehicle information by constantly monitoring different vehicle systems. The message center may display a warning message pertaining to the system in which a fault has been detected. The message center provides the following features: Information menu - Setup menu - Warning messages The message center information can be selected through a set of 3 buttons: INFO - RESET - SETUP The setup display time-outs and defaults to the blank display function. The temporary alert display interrupts the current display to show the status of an event that has just happened. The warning display interrupts the current display until cleared or reset by the driver. Compass Display The message center provides a compass display and uses directional information sent from the compass module. The compass module is mounted to the underside of the interior rear view mirror or integrated into the mirror if equipped with a auto-dimming mirror or a rear video camera display mirror. Information Displays The information displays are non-timed modes. The selected mode remains on until the driver presses a message center button to change the mode, or it is overridden by another mode. The information display modes are: Odometer - Trip odometer - Compass - Outside air temperature - Distance to empty - Average fuel economy - Elapsed trip time Setup Displays The setup displays are timed modes and default back to the blank display function. The setup display modes are: System check - English/metric units - Autolocks on, autolocks off - Language (English, French or Spanish) System Check Displays The system check function monitors a variety of systems and displays an OK message or warning message if a fault is detected in the monitored system. The systems monitored are as follows: Fuel level - Engine temperature - Oil pressure - Brake fluid level - Charging system Warning Messages The warning messages can interrupt the display until cleared or reset by the driver. The system uses 3 types of warning messages: single cycle, non-renewable, and repetitive. The single cycle of warning messages display once whenever the ignition switch is turned to the ON position or a fault occurs in a system. They can be cleared by pressing the RESET button. The single cycle warning message is: DOOR AJAR The non-renewable warning messages are displayed at a fixed interval whenever the ignition switch is turned to the ON position or is in the ACC position. To remove a repetitive warning message, press the RESET button. The message only recurs after 10 minutes or when the warning condition is corrected. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 8465 The non-renewable warning messages are: LOW FUEL LEVEL - CHECK CHARGING SYSTEM - CHECK TRACTION CONTROL - LOW BRAKE FLUID - LOW OIL PRESSURE - CHECK ENGINE TEMPERATURE - REDUCED ENGINE POWER - STOP ENGINE SAFELY The repetitive warning messages display whenever the ignition switch is turned to the ON position and a fault occurs in a system. The fault must be corrected to clear the warning messages. The repetitive warning messages are: CHECK FUEL CAP - TRANSMISSION - LOW TIRE PRESSURE - TIRE PRESSURE MONITOR FAULT - TIRE PRESSURE SENSOR FAULT Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Driver/Vehicle Information Display: Initial Inspection and Diagnostic Overview Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the data link connector (DLC). 5. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to diagnose no communication with the scan tool. 6. If the scan tool does not communicate with the vehicle: - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus (Module Communications Network) to diagnose no response from the PCM. 7. Carry out the network test. - If the scan tool responds with no communication for one or more modules, refer to Information Bus (Module Communications Network). - If the network test passes, retrieve and record the continuous memory DTCs. 8. Clear the continuous DTCs and carry out the self-test diagnostics for the PCM and the instrument cluster (IC). 9. If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to Body Control Systems (Multifunction Electronic Control Module). See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Information and Message Center 10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Principles of Operation PRINCIPLES OF OPERATION The message center is an integral part of the instrument cluster (IC) that receives and acts upon much of the same information that is input and used to operate the instrument cluster (IC) gauges, informational indicators, and warning indicators. The message center, located in the instrument cluster (IC) is a vacuum fluorescent 2-line display. The message center electronic functions use both hardwired and the network communication circuitry to transmit and receive information. Whenever conditions are present that require a warning message, the message center replaces the last selected display with the new warning display. Warning messages are generally associated with other observable instrument cluster (IC) indications. For example, when a door is opened, the message center displays the message DOOR AJAR along with the door ajar warning indicator. This allows the message center to be a more informative supplement to the instrument cluster (IC) gauges and indicators. It is very important to understand: - where the input (command) originates. - all the information (messages) necessary in order for a feature to operate. - which module(s) receive(s) the input or command message. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8468 - if the module that received the input (message) controls the output of the feature, or if it outputs a message over the CAN to another module. - which module controls the output of the feature. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8469 Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8470 Symptom Chart (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8471 Symptom Chart (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8472 Symptom Chart (Part 4) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8473 Driver/Vehicle Information Display: Pinpoint Tests Test A: The Message Center Is Not Operating Correctly PINPOINT TEST A: THE MESSAGE CENTER IS NOT OPERATING CORRECTLY Normal Operation The message center display is integrated into the lower RH corner of the instrument cluster (IC). The instrument cluster (IC) odometer, trip odometer, compass, outside air temperature and message center displays are contained in the same window. The message center switch is hardwired to the instrument cluster (IC) through circuits 1411 (GY/OG) and 1396 (VT/WH). The message center switches use a different resistance value for each switch, allowing the instrument cluster (IC) to determine which switch is pressed. This pinpoint test is intended to diagnose the following: - Instrument cluster (IC) - Message center switch A1-A3 Test B: The Message Center Switch Does Not Operate Correctly PINPOINT TEST B: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY Normal Operation The message center functionality is controlled through the message center switch, which is hardwired to the instrument cluster (IC) through the input circuit 1411 (GY/OG) and the return circuit 1396 (VT/WH). There are 3 message center switch buttons with each button operating a switch that uses different resistance values. The instrument cluster (IC) sends out a reference voltage to the message center switch on the input circuit and monitors the voltage drop when a message center switch button is pressed. The voltage drop will vary depending upon the resistance of each button, providing a specific indication to the instrument cluster (IC) which switch is pressed. - DTC B1209 (EIC Switch-2 Assembly Circuit Failure) - sets on-demand in the instrument cluster (IC) if any of the buttons on the message center are stuck or pressed during the self-test. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Instrument cluster (IC) - Message center switch Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8474 B1-B4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8475 B4-B6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8476 B6-B7 Test C: The Compass Is Inoperative PINPOINT TEST C: THE COMPASS IS INOPERATIVE Normal Operation The compass module (without auto-dimming interior rear view mirror) or interior rear view mirror (with auto-dimming interior rear view mirror) receives voltage from the central junction box (CJB) through circuit 294 (WH/LB) and is grounded through circuit 875 (BK/LB). The compass module (without auto-dimming interior rear view mirror) or interior rear view mirror (with auto-dimming interior rear view mirror) communicates vehicle direction to the instrument cluster (IC) to be displayed in the message center. The compass module (without auto-dimming interior rear view mirror) or interior rear view mirror (with auto-dimming interior rear view mirror) uses circuits 702 (WH/BK) and 703 (WH/OG) to communicate to the instrument cluster (IC). - DTC U2013 (Compass Module is Not Responding) - is a continuous memory DTC that sets in the instrument cluster (IC) if the compass module (without auto-dimming interior rear view mirror) or interior rear view mirror (with auto-dimming interior rear view mirror) does not send the compass data to the instrument cluster (IC). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Compass module (without auto-dimming mirror) - Interior rear view mirror (with auto-dimming mirror) - Instrument cluster (IC) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8477 C1-C2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8478 C2-C4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8479 C4-C6 Test D: The Compass Is Inaccurate PINPOINT TEST D: THE COMPASS IS INACCURATE Normal Operation The compass module (without auto-dimming interior rear view mirror) or interior rear view mirror (with auto-dimming interior rear view mirror) communicates vehicle direction to the instrument cluster (IC) to be displayed in the message center through circuits 702 (WH/BK) and 703 (WH/OG). The magnetic fields generated by the earths north and south poles are divided into zones that differ from each other with respect to how the magnetic fields appear. The magnetic north can change by up to 4 degrees between zones and become noticeable across multiple zones. The compass zone must be set to the correct zone for the compass to read accurately. Factors within the vehicle may affect the ability of the compass module to accurately read the magnetic north. Calibrating the compass allows the compass module to compensate for vehicle factors that influence the accuracy of the compass. NOTE: Outside factors such as bridges, steel structures, tall buildings and power lines also affect compass accuracy. This pinpoint test is intended to diagnose the following: - Compass zone setting - Compass calibration Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8480 - Vehicle magnetization - Compass module (without auto-dimming mirror) - Interior rear view mirror (with auto-dimming mirror) D1-D2 Test E: The Transmission Message Is Inoperative PINPOINT TEST E: THE TRANSMISSION MESSAGE IS INOPERATIVE Normal Operation The instrument cluster (IC) and message center receive transmission data from the PCM over the high speed controller area network (HS-CAN) communication bus. When a concern exists with the transmission, the PCM provides a command signal to the message center to display the transmission warning message. This pinpoint test is intended to diagnose the following: - Instrument cluster (IC) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8481 E1-E2 Test F: The Check Fuel Cap Message Is Inoperative/Always Displayed PINPOINT TEST F: THE CHECK FUEL CAP MESSAGE IS INOPERATIVE/ALWAYS DISPLAYED Normal Operation The PCM monitors the fuel tank evaporative emission system for significant leaks that occur following refueling of the vehicle. Once the PCM detects a fuel vapor leak, the PCM sends the instrument cluster (IC) a network message over the communication network to turn on the check fuel cap warning message display. DTC P0457 sets in the PCM following a successful cruise test, which is initiated when the vehicle is driven at a steady speed above 64 km/h (40 mph) for a duration of approximately 4-5 minutes. If the PCM is unable to successfully run the cruise test, the instrument cluster (IC) does not receive the check fuel cap network message and the check fuel cap message display remains off. - DTC P0457 (Evaporative Emission System Leak Detected) (fuel cap loose/off) - sets in the PCM if a fuel tank pressure change greater than -23.7 kPa (-7 in-Hg) of vacuum within 30 seconds after refueling occurs, or there is an excessive purge (fuel vapor) flow of greater than 454 g (1.0 lb) per minute. This pinpoint test is intended to diagnose the following: - PCM - Instrument cluster (IC) F1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8482 F2-F3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Page 8483 Driver/Vehicle Information Display: Service and Repair MESSAGE CENTER SWITCH Removal and Installation 1. Remove the message center switch. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Page 8484 Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Filler Cap Warning Indicator > Component Information > Description and Operation Fuel Filler Cap Warning Indicator: Description and Operation CHECK FUEL CAP INDICATOR The check fuel cap indicator is a communications network message sent by the PCM. The PCM sends the message to illuminate the lamp when the strategy determines there is a concern in the EVAP system due to the fuel filler cap or capless fuel tank filler pipe not being sealed correctly. This would be detected by the inability to pull vacuum in the fuel tank, after a fueling event. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8492 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8493 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8494 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8495 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8496 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8497 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8498 Fuel Gauge: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8499 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8500 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8501 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8502 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8503 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8504 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-2-9 > Feb > 08 > Fuel System Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 Fuel Gauge Sender: Customer Interest Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 TSB 08-2-9 02/04/08 ERRATIC FUEL GAUGE OPERATION - MIL ON - DTCS P0460/P0463 OR INSTRUMENT CLUSTER MODULE DTC B1201 - VEHICLES BUILT BEFORE 12/3/2007 FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT vehicles, built before 12/3/2007, may exhibit erratic fuel gauge operation or illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P0460 or P0463, and/or Instrument Cluster Module DTC B1201. This may be caused by sulphur contamination in the fuel causing an open or high resistance in the fuel level sender. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Install a new fuel level sender following the service procedure instruction sheet provided in the fuel sender kit. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 080209A 2004-2008 F-150, 1.9 Hrs. 2006-2008 Mark LT: Install New Fuel Level Sender, Includes Time To Remove Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-2-9 > Feb > 08 > Fuel System Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 > Page 8513 And Install Fuel Tank (Do Not Use With 9002A, 9002A4, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-2-9 > Feb > 08 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 TSB 08-2-9 02/04/08 ERRATIC FUEL GAUGE OPERATION - MIL ON - DTCS P0460/P0463 OR INSTRUMENT CLUSTER MODULE DTC B1201 - VEHICLES BUILT BEFORE 12/3/2007 FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT vehicles, built before 12/3/2007, may exhibit erratic fuel gauge operation or illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P0460 or P0463, and/or Instrument Cluster Module DTC B1201. This may be caused by sulphur contamination in the fuel causing an open or high resistance in the fuel level sender. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Install a new fuel level sender following the service procedure instruction sheet provided in the fuel sender kit. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 080209A 2004-2008 F-150, 1.9 Hrs. 2006-2008 Mark LT: Install New Fuel Level Sender, Includes Time To Remove Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-2-9 > Feb > 08 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 > Page 8519 And Install Fuel Tank (Do Not Use With 9002A, 9002A4, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 8520 View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 8521 Fuel Gauge Sender: Diagrams C4074 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 8522 C4330 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 8523 Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 8524 The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Fuel Pump (FP) Module and Reservoir The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module Fuel Gauge Sender: Service and Repair Fuel Pump Module FUEL PUMP MODULE Special Tool(s) Special Tool(s) Removal WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 8527 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the fuel tank. 3. Using soapy water, clean a minimum of 76 mm (3 in) surface area around the fuel pump module. 4. Disconnect the fuel supply and fuel vapor tube assembly quick connect couplings at the fuel pump module and remove the fuel supply and fuel vapor tube assembly from the fuel tank. 5. Using the special tool, remove the fuel pump module locking ring. 6. Lift the fuel pump module out of the fuel tank enough to disconnect the internal fuel tank grade vent valves-to-fuel pump quick connect coupling. 7. CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter. Remove the fuel pump module. 8. Remove and discard the fuel pump module O-ring seal. Installation 1. NOTE: Lubricate the new fuel pump module O-ring seal with clean engine oil prior to installation. Install a new fuel pump module O-ring seal. 2. CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter. Install the fuel pump module into the fuel tank enough to connect the internal fuel tank grade vent valves-to-fuel pump quick connect coupling. 3. Install the fuel pump module the rest of the way into the fuel tank. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 8528 4. Using the special tool, install the fuel pump module locking ring. 5. NOTE: - The fuel pump module does not come equipped with a fuel pump module cover from the factory. The fuel pump module cover is only installed after service to the fuel pump module is performed. - Before installing the fuel pump module cover, make sure it fits around all fuel and vapor ports and electrical connectors and allows enough clearance to install the fuel and vapor tube assembly and the fuel pump module electrical connector. - Make sure a minimum of 76 mm (3 in) surface area is properly cleaned of all gas, oil and foreign material before installing the fuel pump module cover. Install a fuel pump module cover over the fuel pump module and locking ring. 6. Install the fuel supply and fuel vapor tube assembly onto the fuel tank and connect the fuel supply and fuel vapor tube assembly quick connect couplings at the fuel pump module. 7. Install the fuel tank. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 8529 Fuel Gauge Sender: Service and Repair Fuel Level Sender FUEL LEVEL SENDER Removal WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. 1. Remove the fuel pump module. 2. NOTE: Note the routing of the fuel level sender wire for installation. Unwrap the fuel level sender wire from the rest of the fuel pump module wire harness. 3. Remove the heat shrink tube covering the electrical connector. 4. Disconnect the electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 8530 5. NOTE: Gasoline shown, flexible fuel similar. Remove the screw and lift up to remove the fuel level sender. Installation All vehicles 1. Route the fuel level sender wire through the center of the fuel pump module. Gasoline vehicles 2. NOTE: - Both fuel level sender wires must be routed behind the metal fuel level sender plate. - The grounding eyelet must be on the front side of the fuel level sender. Hook the fuel level sender on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. Flexible fuel vehicles Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 8531 3. NOTE: - One fuel level sender wire routes behind the fuel level sender and one routes along the left side of the fuel level sender. - The grounding eyelet must be on the front side of the fuel level sender. Hook the fuel level sender on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. Clip the wire into the clip on the fuel pump module. All vehicles 4. Slide the heat shrink tube onto the wire harness and connect the electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, heat the heat shrink tube. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 8532 6. Wrap the fuel level sender wire around the fuel pump module wire harness to make sure the wire will not interfere with the movement of the fuel gauge sending unit float arm. 7. Install the fuel pump module. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) Depowering Procedure WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, remove the trim panel, the cover and the RCM fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install the RCM fuse 19 (10A) to the CJB and install the cover and trim panel. 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8538 4. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8539 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Never probe the electrical connectors on air bag, safety canopy or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. - To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: - The air bag warning indicator illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, remove the trim panel, the cover, and the RCM fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. 7. Remove the driver air bag module. 8. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8540 9. While pushing in on the 2 glove compartment door tabs, position the glove compartment downward. 10. Through the glove compartment opening, release the tabs and disconnect the LH passenger air bag module electrical connector. 11. Attach the restraint system diagnostic tool to the vehicle harness side of the LH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8541 12. Through the glove compartment opening, release the tabs and disconnect the RH passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the RH passenger air bag module electrical connector. 14. Install the RCM fuse 19 (10A) to the CJB. 15. Connect the battery ground cable. Reactivation 1. Remove the RCM fuse 19 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. 3. Remove the restraint system diagnostic tool from the vehicle harness side of the RH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8542 4. Through the glove compartment opening, connect the RH passenger air bag module electrical connector. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the LH passenger air bag module electrical connector. 6. Through the glove compartment opening, connect the LH passenger air bag module electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8543 7. Close the glove compartment. 8. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 9. Turn the ignition switch from OFF to ON. 10. Install the RCM fuse 19 (10A) to the CJB and install the cover and trim panel. 11. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 12. Prove out the SRS as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the air bag warning indicator will: fail to light. - remain lit continuously. - flash at a 5Hz rate (RCM not configured). The air bag warning indicator might not light until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM using a scan tool. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair Instrument Panel Bulb: Service and Repair WARNING INDICATOR BULB Removal and Installation 1. Remove the instrument cluster (IC). 2. Remove the 7 screws and the instrument cluster (IC) shield. 3. NOTE: One of the base instrument clusters (IC) shown, other instrument clusters (IC) are similar. Remove the warning indicator bulb(s) in question. Rotate the bulb one quarter turn counterclockwise and lift it out from the instrument cluster. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages Low Tire Pressure Indicator: Testing and Inspection Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages > Page 8551 Low Tire Pressure Indicator: Testing and Inspection Tire Pressure Monitoring System (TPMS) Indicator Illuminates Continuously Tire Pressure Monitoring System (TPMS) Indicator Illuminates Continuously NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPMS functionality before carrying out any diagnosis. NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressures for front and rear tires, tire rotation will not affect the system. 1. The TPMS indicator remains on continuously for the following condition: ^ Low Tire Pressure - The TPMS indicator is illuminated solid and the message center displays LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low. When this condition exists, the tire pressure must be adjusted to the recommended cold pressure as indicated on the vehicle certification label. 2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been stationary for more than 30 minutes, it will be necessary to wake up the sensors so they will transmit the latest tire pressure information to the VSM. If the vehicle has been stationary for more than 30 minutes, refer to the Tire Pressure Monitoring System (TPMS) Sensor Activation procedure. See: Tire Monitoring System/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages > Page 8552 Low Tire Pressure Indicator: Testing and Inspection Tire Pressure Monitoring System (TPMS) Indicator Flashes Tire Pressure Monitoring System (TPMS) Indicator Flashes The TPMS indicator flashes for 70 seconds and then remains ON solid when the ignition key is turned to the ON position for the following conditions: 1. Tire Pressure Sensor Fault - If equipped, the message center will display TIRE SENSOR FAULT when a tire pressure sensor is malfunctioning. GO to Symptom Chart. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures 2. No communication with the VSM (TPMS is integral to the VSM) - The TPMS indicator is illuminated when the instrument cluster has received no signals from the VSM for more than 5 seconds. If equipped, the message center displays TIRE MONITOR FAULT. GO to Symptom Chart. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures 3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE MONITOR FAULT when the tire pressure monitoring system is malfunctioning or communication with the instrument cluster has been lost. GO to Symptom Chart. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair SERVICE ENGINE SOON INDICATOR The Service engine soon indicator light illuminates when the ignition is first turned to the "ON" position to check the bulb. Solid illumination after the engine is started indicates the On Board Diagnostics System (OBD-II) has detected a malfunction. If the light is blinking, engine misfire is occurring which could damage your catalytic converter. Drive in a moderate fashion (avoid heavy acceleration and deceleration) and have your vehicle serviced immediately. CAUTION: Under engine misfire conditions, excessive exhaust temperatures could damage the catalytic converter, the fuel system, interior floor coverings or other vehicle components, possibly causing a fire. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) Check Engine, Service Engine Soon, Or ISO Standard Engine Symbol The MIL notifies the driver that the powertrain control module (PCM) has detected an on board diagnostic (OBD) emission-related component or system concern. When this occurs, an OBD diagnostic trouble code (DTC) sets. - The MIL is located in the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or the international standards organization (ISO) standard engine symbol. - The MIL is illuminated during the instrument cluster prove out for approximately 4 seconds. - The MIL remains illuminated after instrument cluster prove out if: an emission-related concern and DTC exists. - the PCM does not send a control message to the instrument cluster (applications with the MIL controlled through the communication link). - the PCM is operating in the hardware limited operation strategy (HLOS). - The MIL remains off during the instrument cluster prove out if an indicator or instrument cluster concern is present. - To turn off the MIL after a repair, a reset command from the scan tool must be sent, or 3 consecutive drive cycles must be completed without a concern. - For all MIL concerns, go to Symptom Charts. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures - If the MIL flashes at a steady rate, a severe misfire condition may exist. - If the MIL flashes erratically, the PCM can reset while cranking if the battery voltage is low. - The MIL flashes after a period of time with the key in the RUN position (engine not running) if DTC P1000 is set. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair Ford provides no information related to a Oil Change Reminder Lamp for this vehicle Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations View 151-4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 8565 View 151-6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 8566 View 151-8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 8567 C103 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 8568 Oil Pressure Sender: Service and Repair Engine Oil Pressure (EOP) Switch Engine Oil Pressure (EOP) Switch Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the engine oil pressure (EOP) switch. ^ To install, tighten to 18 Nm (13 lb-ft). 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Diagrams C2024 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 8575 C2015 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 8576 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the parking brake warning indicator switch electrical connector. 3. Remove the parking brake warning indicator switch screw and the switch. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Description and Operation > Belt-Minder(R) Seat Belt Reminder Buzzer: Description and Operation Belt-Minder(R) BELT-MINDER(R) The Belt-Minder(R) feature is a supplemental warning to the safety belt warning function. This feature provides an additional reminder to the driver that the driver and/or passenger safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning indicator in the instrument cluster. The passenger Belt-Minder(R) feature is activated only when the occupant classification sensor (OCS) system detects a passenger in the right front seat and the passenger weight exceeds a programmed limit. To activate or deactivate the Belt-Minder(R) feature, refer to Instrument Panel, Gauges and Warning Indicators. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Description and Operation > Belt-Minder(R) > Page 8581 Seat Belt Reminder Buzzer: Description and Operation Safety Belt Warning Indicator and Chime SAFETY BELT WARNING INDICATOR AND CHIME The warning indicator and chime are reminders to fasten the safety belt. The system operates as follows: - If the driver safety belt is not buckled in the first 6 seconds after the ignition switch is turned to the RUN or START position, the warning indicator will illuminate and the chime will toggle from ON to OFF for 6 seconds, for one minute. - If the driver safety belt is buckled while the warning indicator is on and the chime is sounding, both the warning indicator and chime will turn off. - If the safety belt is buckled before the ignition is turned to the ON position, neither the warning indicator nor the chime will turn on. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation > Belt-Minder(R) Seat Belt Reminder Lamp: Description and Operation Belt-Minder(R) BELT-MINDER(R) The Belt-Minder(R) feature is a supplemental warning to the safety belt warning function. This feature provides an additional reminder to the driver that the driver and/or passenger safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning indicator in the instrument cluster. The passenger Belt-Minder(R) feature is activated only when the occupant classification sensor (OCS) system detects a passenger in the right front seat and the passenger weight exceeds a programmed limit. To activate or deactivate the Belt-Minder(R) feature, refer to Instrument Panel, Gauges and Warning Indicators. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation > Belt-Minder(R) > Page 8586 Seat Belt Reminder Lamp: Description and Operation Safety Belt Warning Indicator and Chime SAFETY BELT WARNING INDICATOR AND CHIME The warning indicator and chime are reminders to fasten the safety belt. The system operates as follows: - If the driver safety belt is not buckled in the first 6 seconds after the ignition switch is turned to the RUN or START position, the warning indicator will illuminate and the chime will toggle from ON to OFF for 6 seconds, for one minute. - If the driver safety belt is buckled while the warning indicator is on and the chime is sounding, both the warning indicator and chime will turn off. - If the safety belt is buckled before the ignition is turned to the ON position, neither the warning indicator nor the chime will turn on. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Left Front View 151-30 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Left Front > Page 8592 View 151-31 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Left Front > Page 8593 View 151-33 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front C526 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8596 C602 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8597 C715 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8598 C820 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 8599 Door Switch: Service and Repair DOOR AJAR SWITCH Removal and Installation 1. Remove the front or rear door latch. 2. Release the locking tab and remove the door ajar switch. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-2-9 > Feb > 08 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 Fuel Gauge Sender: Customer Interest Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 TSB 08-2-9 02/04/08 ERRATIC FUEL GAUGE OPERATION - MIL ON - DTCS P0460/P0463 OR INSTRUMENT CLUSTER MODULE DTC B1201 - VEHICLES BUILT BEFORE 12/3/2007 FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT vehicles, built before 12/3/2007, may exhibit erratic fuel gauge operation or illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P0460 or P0463, and/or Instrument Cluster Module DTC B1201. This may be caused by sulphur contamination in the fuel causing an open or high resistance in the fuel level sender. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Install a new fuel level sender following the service procedure instruction sheet provided in the fuel sender kit. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 080209A 2004-2008 F-150, 1.9 Hrs. 2006-2008 Mark LT: Install New Fuel Level Sender, Includes Time To Remove Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-2-9 > Feb > 08 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 > Page 8608 And Install Fuel Tank (Do Not Use With 9002A, 9002A4, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-2-9 > Feb > 08 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 TSB 08-2-9 02/04/08 ERRATIC FUEL GAUGE OPERATION - MIL ON - DTCS P0460/P0463 OR INSTRUMENT CLUSTER MODULE DTC B1201 - VEHICLES BUILT BEFORE 12/3/2007 FORD: 2004-2008 F-150 LINCOLN: 2006-2008 Mark LT ISSUE Some 2004-2008 F-150 and 2006-2008 Mark LT vehicles, built before 12/3/2007, may exhibit erratic fuel gauge operation or illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P0460 or P0463, and/or Instrument Cluster Module DTC B1201. This may be caused by sulphur contamination in the fuel causing an open or high resistance in the fuel level sender. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Install a new fuel level sender following the service procedure instruction sheet provided in the fuel sender kit. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 080209A 2004-2008 F-150, 1.9 Hrs. 2006-2008 Mark LT: Install New Fuel Level Sender, Includes Time To Remove Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-2-9 > Feb > 08 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0460/P0463 > Page 8614 And Install Fuel Tank (Do Not Use With 9002A, 9002A4, 9002A6) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 42 Disclaimer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 8615 View 151-27 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 8616 Fuel Gauge Sender: Diagrams C4074 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 8617 C4330 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 8618 Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 8619 The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Fuel Pump (FP) Module and Reservoir The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module Fuel Gauge Sender: Service and Repair Fuel Pump Module FUEL PUMP MODULE Special Tool(s) Special Tool(s) Removal WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. - When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 8622 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the fuel tank. 3. Using soapy water, clean a minimum of 76 mm (3 in) surface area around the fuel pump module. 4. Disconnect the fuel supply and fuel vapor tube assembly quick connect couplings at the fuel pump module and remove the fuel supply and fuel vapor tube assembly from the fuel tank. 5. Using the special tool, remove the fuel pump module locking ring. 6. Lift the fuel pump module out of the fuel tank enough to disconnect the internal fuel tank grade vent valves-to-fuel pump quick connect coupling. 7. CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter. Remove the fuel pump module. 8. Remove and discard the fuel pump module O-ring seal. Installation 1. NOTE: Lubricate the new fuel pump module O-ring seal with clean engine oil prior to installation. Install a new fuel pump module O-ring seal. 2. CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter. Install the fuel pump module into the fuel tank enough to connect the internal fuel tank grade vent valves-to-fuel pump quick connect coupling. 3. Install the fuel pump module the rest of the way into the fuel tank. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 8623 4. Using the special tool, install the fuel pump module locking ring. 5. NOTE: - The fuel pump module does not come equipped with a fuel pump module cover from the factory. The fuel pump module cover is only installed after service to the fuel pump module is performed. - Before installing the fuel pump module cover, make sure it fits around all fuel and vapor ports and electrical connectors and allows enough clearance to install the fuel and vapor tube assembly and the fuel pump module electrical connector. - Make sure a minimum of 76 mm (3 in) surface area is properly cleaned of all gas, oil and foreign material before installing the fuel pump module cover. Install a fuel pump module cover over the fuel pump module and locking ring. 6. Install the fuel supply and fuel vapor tube assembly onto the fuel tank and connect the fuel supply and fuel vapor tube assembly quick connect couplings at the fuel pump module. 7. Install the fuel tank. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 8624 Fuel Gauge Sender: Service and Repair Fuel Level Sender FUEL LEVEL SENDER Removal WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury. 1. Remove the fuel pump module. 2. NOTE: Note the routing of the fuel level sender wire for installation. Unwrap the fuel level sender wire from the rest of the fuel pump module wire harness. 3. Remove the heat shrink tube covering the electrical connector. 4. Disconnect the electrical connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 8625 5. NOTE: Gasoline shown, flexible fuel similar. Remove the screw and lift up to remove the fuel level sender. Installation All vehicles 1. Route the fuel level sender wire through the center of the fuel pump module. Gasoline vehicles 2. NOTE: - Both fuel level sender wires must be routed behind the metal fuel level sender plate. - The grounding eyelet must be on the front side of the fuel level sender. Hook the fuel level sender on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. Flexible fuel vehicles Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 8626 3. NOTE: - One fuel level sender wire routes behind the fuel level sender and one routes along the left side of the fuel level sender. - The grounding eyelet must be on the front side of the fuel level sender. Hook the fuel level sender on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. Clip the wire into the clip on the fuel pump module. All vehicles 4. Slide the heat shrink tube onto the wire harness and connect the electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, heat the heat shrink tube. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module > Page 8627 6. Wrap the fuel level sender wire around the fuel pump module wire harness to make sure the wire will not interfere with the movement of the fuel gauge sending unit float arm. 7. Install the fuel pump module. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 8631 C2015 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 8632 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the parking brake warning indicator switch electrical connector. 3. Remove the parking brake warning indicator switch screw and the switch. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments Selector Lever Cable Adjustment Vehicles equipped with a floor mounted selector lever 1. Place the selector lever in the 1st position toward the rear of the vehicle. 2. Move the selector lever forward 2 detents. This should be the (D) position. Vehicles equipped with a column mounted selector lever 3. Rotate the selector lever clockwise until it bottoms out (1st gear), then rotate the selector lever counterclockwise 2 detent positions ((D) position). 4. Hang a 1.4 kg (3 lb) weight on the selector lever. All vehicles 5. With the vehicle in NEUTRAL, position it on a hoist. Vehicles equipped with a floor mounted selector lever 6. Rotate the cable adjustment lock upward and disconnect the selector lever cable from the manual control lever. Vehicles equipped with a column mounted selector lever 7. Slide the selector lever cable adjustment lock upwards and remove the cable from the manual control lever. 8. Rotate the manual control lever forward until the travel stops. Then rotate the manual control lever back 2 detents to the (D) position. Vehicles equipped with a floor mounted selector lever Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Adjustments > Page 8636 9. NOTE: Check to be sure that the selector lever cable retainer is correctly installed in the selector lever cable bracket. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the manual control lever and rotate the lock downward to lock the adjuster. Vehicles equipped with a column mounted selector lever 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed. Connect the selector lever cable to the manual control lever and slide the lock downward to lock the adjuster. 11. Verify that the engine will start in PARK and NEUTRAL. Verify that the reverse lamps will illuminate in the REVERSE position. If not, check the adjustment of the transmission range (TR) sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages Low Tire Pressure Indicator: Testing and Inspection Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages > Page 8642 Low Tire Pressure Indicator: Testing and Inspection Tire Pressure Monitoring System (TPMS) Indicator Illuminates Continuously Tire Pressure Monitoring System (TPMS) Indicator Illuminates Continuously NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPMS functionality before carrying out any diagnosis. NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressures for front and rear tires, tire rotation will not affect the system. 1. The TPMS indicator remains on continuously for the following condition: ^ Low Tire Pressure - The TPMS indicator is illuminated solid and the message center displays LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low. When this condition exists, the tire pressure must be adjusted to the recommended cold pressure as indicated on the vehicle certification label. 2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been stationary for more than 30 minutes, it will be necessary to wake up the sensors so they will transmit the latest tire pressure information to the VSM. If the vehicle has been stationary for more than 30 minutes, refer to the Tire Pressure Monitoring System (TPMS) Sensor Activation procedure. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages > Page 8643 Low Tire Pressure Indicator: Testing and Inspection Tire Pressure Monitoring System (TPMS) Indicator Flashes Tire Pressure Monitoring System (TPMS) Indicator Flashes The TPMS indicator flashes for 70 seconds and then remains ON solid when the ignition key is turned to the ON position for the following conditions: 1. Tire Pressure Sensor Fault - If equipped, the message center will display TIRE SENSOR FAULT when a tire pressure sensor is malfunctioning. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 2. No communication with the VSM (TPMS is integral to the VSM) - The TPMS indicator is illuminated when the instrument cluster has received no signals from the VSM for more than 5 seconds. If equipped, the message center displays TIRE MONITOR FAULT. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE MONITOR FAULT when the tire pressure monitoring system is malfunctioning or communication with the instrument cluster has been lost. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Module > Component Information > Locations Tire Pressure Module: Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Module > Component Information > Locations > Page 8647 View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Module > Component Information > Locations > Page 8648 Tire Pressure Module: Diagrams C3008A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Module > Component Information > Locations > Page 8649 C3008B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the vehicle security module (VSM). Refer to Tire Pressure Monitoring System (TPMS) Sensor Activation. See: Testing and Inspection/Programming and Relearning NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with tire pressure monitor system (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the activation tool, attempt to activate the same sensor with the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least 1/4 of a turn and attempt to activate the same sensor again. NOTE: The VSM has a 2 minute time limit between sensor responses. If the VSM does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the tire pressure must be adjusted and the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressures for front and rear tires, tire rotation will not affect the system. 1. NOTE: Click here to view an animated version of this procedure. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. ^ The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. 6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the activation tool must remain in place 180 degrees from the valve stem. Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the special tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the VSM. Click here to view an animated version of this procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 8654 7. Within 2 minutes of the horn sounding, place the activation tool on the RF tire sidewall opposite (180°) from the valve stem to train the RF tire pressure sensor. 8. NOTE: Do not wait more than 2 minutes between training each sensor or the VSM will time out and the entire procedure must be repeated. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor IDs trained to the VSM and document them on the applicable warranty claim. 10. NOTE: This step is required to clear DTC C2780, cause the VSM to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed VSM. If the sensors are being trained due to the installation of a new VSM, clear any DTCs and perform the VSM on-demand self test. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 8655 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool against the LF tire sidewall 180 degrees from the tire valve stem. 3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the activation tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. 1. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. Click here to view an animated version of this procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 8658 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. Click here to view an animated version of this procedure. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor may occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 8659 3. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 8660 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Part 1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 8661 Part 1 Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter, but all strap kits share the same base part number. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. Remove a factory installed strap in the following sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item on both sides of the buckle approximately 25 mm (0.98 in) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. 3. To remove a dealer-installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 4. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Click here to view an animated version of this procedure. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers may damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 8662 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180 degrees from the valve stem. Click here to view a video version of this procedure. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. Click here to view an animated version of this procedure. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13-26 mm (0.5-1.0 in) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 lb-in). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 8663 6. CAUTION: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 8671 C286 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 8672 Ambient Light Sensor: Service and Repair LIGHT SENSOR Removal and Installation 1. Remove the defroster grille panel. - Disconnect the electrical connector. 2. Remove the 2 screws and the light sensor. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Reversing Lamps Switch View 151-12 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Reversing Lamps Switch > Page 8678 Backup Lamp Switch: Locations Digital Transmission Range (DTR) Sensor View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Reversing Lamps Switch > Page 8679 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Digital Transmission Range (DTR) Sensor C167 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Digital Transmission Range (DTR) Sensor > Page 8682 C169 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8687 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8688 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8689 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8690 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8691 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8692 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8693 Brake Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8694 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8695 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8696 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8697 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8698 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8699 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8700 Brake Lamp: Connector Views C4032 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8701 C4035 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8702 Brake Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 90-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8703 90-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Brake Lamp: Initial Inspection and Diagnostic Overview Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the concern is not visually evident, verify the symptom. GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Principles of Operation PRINCIPLES OF OPERATION When the brake pedal is applied, the stoplamp switch routes voltage directly to the high mounted stoplamp and the multifunction switch. The multifunction switch then routes voltage to the rear lamps. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8706 Symptom Chart Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8707 Brake Lamp: Pinpoint Tests Test K: All The Stoplamps Are Inoperative PINPOINT TEST K: ALL THE STOPLAMPS ARE INOPERATIVE Normal Operation The stoplamp switch is supplied voltage through circuit 10 (LG/RD). When the brake pedal is applied, the stoplamp switch routes voltage to circuit 511 (LG). Circuit 511 (LG) supplies voltage to the multifunction switch and the high mounted stoplamp. The multifunction switch internally routes the voltage (when in the NEUTRAL position) to circuits 9 (LG/OG) (LH stoplamp) and 5 (OG/LB) (RH stoplamp). Circuits 9 (LG/OG) and 5 (OG/LB) are routed through the central junction box (CJB) to the LH and RH stoplamps, accordingly. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Stoplamp switch - CJB K1-K2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8708 K2-K3 Test L: One Or More Stoplamps Are Inoperative PINPOINT TEST L: ONE OR MORE STOPLAMPS ARE INOPERATIVE Normal Operation When the brake pedal is applied, circuit 511 (LG) supplies voltage to the multifunction switch and the high mounted stoplamp. The multifunction switch internally routes the voltage (when in the NEUTRAL position) to circuits 9 (LG/OG) (LH stoplamp) and 5 (OG/LB) (RH stoplamp). Circuits 9 (LG/OG) and 5 (OG/LB) are routed through the central junction box (CJB) and then to the LH and RH stoplamps, accordingly. The rear stoplamps share a common ground. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - High mounted stoplamp - Multifunction switch - CJB Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8709 L1-L4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8710 L5-L7 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8711 L7-L8 Test M: The Stoplamps Are On Continuously PINPOINT TEST M: THE STOPLAMPS ARE ON CONTINUOUSLY Normal Operation The stoplamp switch is supplied voltage through circuit 10 (LG/RD). When the brake pedal is applied, the stoplamp switch routes voltage to circuit 511 (LG). Circuit 511 (LG) supplies voltage to the PCM, the trailer brake control module (TBCM) (if equipped), the multifunction switch and the high mounted stoplamp. The multifunction switch internally routes the power (when in the NEUTRAL position) to circuits 9 (LG/OG) (LH stoplamp) and 5 (OG/LB) (RH stoplamp). Circuits 9 (LG/OG) and 5 (OG/LB) are routed through the central junction box (CJB) and then to the LH and RH stoplamps, accordingly. Circuits 9 (LG/OG) (LH stoplamp) and 5 (OG/LB) (RH stoplamp) are spliced (and fused) within the CJB to circuits 52 (YE) and 64 (DG), respectively, for the trailer tow stop/turn lamps. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Stoplamp switch - Multifunction switch - CJB - TBCM - PCM Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8712 M1-M4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8713 M5-M8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page 8714 Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8718 C278 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8719 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8720 Brake Light Switch: Service and Repair STOPLAMP SWITCH Removal and Installation 1. Disconnect the battery. 2. Disconnect the stoplamp switch electrical connector. 3. Remove the retainer. 4. Remove the pin. 5. Remove the stoplamp switch. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams C904 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions Courtesy Lamp: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8728 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8729 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8730 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8731 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8732 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8733 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8734 Courtesy Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8735 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8736 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8737 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8738 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8739 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8740 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8741 Courtesy Lamp: Connector Views C901 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8742 C932 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8743 C929 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8744 Courtesy Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 89-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8745 89-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Courtesy Lamp: Initial Inspection and Diagnostic Overview Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage: VISUAL INSPECTION CHART Electrical Bulb(s) - Central junction box (CJB) fuse 24 (15A) - Wiring, terminals or connectors - Door ajar switch(es) - Vehicle security module (VSM) (if equipped with remote keyless entry [RKE]) - Instrument cluster (IC) 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the data link connector (DLC). 5. NOTE: The VCM LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to diagnose no communication with the scan tool. 6. If the scan tool does not communicate with the vehicle: - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus (Module Communications Network) to diagnose no response from the PCM. 7. Carry out the network test. - If the scan tool responds with no communication for one or more modules, refer to Information Bus (Module Communications Network). - If the network test passes, retrieve and record the continuous memory DTCs. 8. Clear the continuous DTCs and carry out the self-test diagnostics for the IC and the VSM. 9. If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to Body Control Systems (Multifunction Electronic Control Module). See: Diagnostic Trouble Code Descriptions 10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Principles of Operation PRINCIPLES OF OPERATION Vehicles Equipped With Remote Keyless Entry (RKE) RKE-equipped vehicles have an illuminated entry feature. The instrument cluster (IC) illuminates the courtesy lamps (and if equipped, the puddle lamps in the exterior mirrors) when an unlock signal is received from the vehicle security module (VSM) through the universal asynchronous receiver transmitter (UART)-based protocol (UBP) network. When active, the illuminated entry feature is canceled when any of the following conditions are met: 25 seconds have elapsed since the illuminated entry feature was activated and the courtesy lamp control is not activated (door ajar or dimmer switch ON). - The IC receives a request from the VSM (remote transmitter LOCK button pressed) and the courtesy lamp control is not activated. - The ignition is in the RUN or START position and the courtesy lamp control is not activated. The IC illuminates the courtesy lamps when any door is open. The courtesy lamps shut off when the doors are closed and the illuminated entry feature is not active or when the vehicle speed is greater than 15 km/h (6 mph). The illuminate entry is not reactivated until the vehicle speed is less than 15 km/h (6 mph) and a new door open signal is received. When any of the doors are open and the dimmer switch is not in the DEFEAT position, the VSM sends a door ajar message over the UBP network to the IC. When the IC receives a door ajar message, the IC illuminates the courtesy lamps. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8748 Vehicles Equipped Without Remote Keyless Entry (RKE) The IC illuminates the courtesy lamps and puddle lamps (if equipped) when any door is open and the dimmer switch is not in the DEFEAT position. The IC turns the courtesy lamps and puddle lamps (if equipped) off when the doors are closed. Demand Lamps/Battery Saver Power to the on-demand lamps, the illuminated vanity mirrors and the map lamps are controlled by the battery saver relay. The battery saver uses the following times for the specific feature to be turned off: Courtesy lamps with the dome lamp off, 10 minutes. - Courtesy lamps with the dome lamp on, 30 minutes. - Warning chimes, 30 minutes. The IC controls the courtesy lamps illuminated entry feature by activating the battery saver relay. The battery saver shutoff time begins when the ignition is turned to the OFF position. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8749 Courtesy Lamp: Diagnostic Trouble Code Descriptions B2499-B2659 B1322-B1574 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8750 Courtesy Lamp: Symptom Related Diagnostic Procedures SYMPTOM CHART NOTE: Only vehicles equipped with remote keyless entry (RKE) will have a vehicle security module (VSM). Symptom Chart Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8751 Courtesy Lamp: Pinpoint Tests Test A: The Courtesy Lamps Are Inoperative PINPOINT TEST A: THE COURTESY LAMPS ARE INOPERATIVE Normal Operation On vehicles equipped with remote keyless entry (RKE), the door ajar switches are hardwired to the vehicle security module (VSM). The VSM monitors the status of all door ajar switches, and when a door is opened, transmits a dome lamp on message to the instrument cluster (IC) through the network, indicating a door has been opened. When the IC receives the dome lamp on message from the VSM, the IC energizes the courtesy lamp circuit, which illuminates the courtesy lamps and, if equipped, the puddle lamps in the exterior mirrors. On vehicles without RKE, the door ajar switches are hardwired to the IC. When the driver or passenger door is opened, the IC receives a ground signal from the driver door ajar switch through circuit 344 (BK/YE), or from the passenger door ajar switch through circuit 345 (BK/PK), and the IC energizes the courtesy lamp circuit, causing the courtesy lamps to illuminate. The dimmer switch is used to turn the courtesy lamps on or off when the doors are closed. The courtesy lamp defeat switch is used to have the courtesy lamps remain off when the doors are open. - DTC B2499 (Courtesy Lamp Output Failure) - is a continuous and on-demand DTC that sets when the courtesy lamp output shorts to ground or has an over-temperature condition. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Dimmer switch - IC A1-A3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8752 A3-A5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8753 A6 Test B: An Individual Courtesy Lamp Is Inoperative PINPOINT TEST B: AN INDIVIDUAL COURTESY LAMP IS INOPERATIVE Normal Operation The instrument cluster (IC) energizes circuit 53 (BK/LB) providing power to the courtesy lamps. The courtesy lamps are grounded through circuit 57 (BK). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Courtesy lamp B1-B2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8754 B2 Continued Test C: The Courtesy Lamps Stay On Continuously PINPOINT TEST C: THE COURTESY LAMPS STAY ON CONTINUOUSLY Normal Operation On vehicles equipped with remote keyless entry (RKE), the vehicle security module (VSM) sends an courtesy lamps on request to the instrument cluster (IC) through the universal asynchronous receiver transmitter (UART)-based protocol (UBP) network circuit 1906 (PK) whenever a door has been opened, the UNLOCK button has been pressed on the remote transmitter, or when an unlock request has been entered with the keyless entry keypad (if equipped). The door ajar switches provide the IC with a signal to energize circuit 53 (BK/LB) when the doors are opened. The courtesy lamps can also be turned on or off with the dimmer switch, which provides a ground signal to the IC through circuit 402 (OG/LG). When the IC receives the courtesy lamps on request from the VSM or the dimmer switch, the IC energizes circuit 53 (BK/LB), which provides power to the courtesy lamps. The courtesy lamps are grounded through circuit 57 (BK). On vehicles without RKE, the IC energizes circuit 53 (BK/LB) when a door has been opened. The door ajar switch provides a signal to the IC, which provides then power to the courtesy lamps. The courtesy lamps can also be turned on or off with the dimmer switch. The courtesy lamps are grounded through circuit 57 (BK), and will remain illuminated until the IC removes voltage from circuit 53 (BK/LB). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Door ajar switch - Dimmer switch - VSM - IC Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8755 C1-C3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8756 C3-C5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8757 C6-C8 Test D: The Demand Lighting Is Inoperative PINPOINT TEST D: THE DEMAND LIGHTING IS INOPERATIVE Normal Operation The instrument cluster (IC) energizes the battery saver relay, located in the central junction box (CJB), through circuit 1005 (VT/OG). The battery saver relay provides voltage to circuit 705 (LG/OG). Circuit 705 (LG/OG) provides voltage to each demand lamp switch, which when activated, provides voltage to the selected demand lamp. The demand lamps are grounded through circuit 57 (BK). The battery saver deactivates when the IC releases the ground from the relay on circuit 1005 (VT/OG), after time-out. The battery saver relay is integral to the CJB. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - CJB - IC Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8758 D1-D3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8759 D3-D5 Test E: An Individual Demand Lamp Is Inoperative PINPOINT TEST E: AN INDIVIDUAL DEMAND LAMP IS INOPERATIVE Normal Operation The instrument cluster (IC) energizes the battery saver relay located in the central junction box (CJB), through circuit 1005 (VT/OG). The battery saver relay provides voltage to circuit 705 (LG/OG). Circuit 705 (LG/OG) provides voltage to all demand lamps. The demand lamps are grounded through circuit 57 (BK). The battery saver deactivates when the IC releases the ground from the relay on circuit 1005 (VT/OG), after time-out. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Interior lamp Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8760 E1-E2 Test F: The Battery Saver Does Not Deactivate After Time-Out PINPOINT TEST F: THE BATTERY SAVER DOES NOT DEACTIVATE AFTER TIME-OUT Normal Operation The instrument cluster (IC) energizes the battery saver relay located in the central junction box (CJB), through circuit 1005 (VT/OG). The battery saver relay provides voltage to circuit 705 (LG/OG). Circuit 705 (LG/OG) provides voltage to all demand lamps. The demand lamps are grounded through circuit 57 (BK). The battery saver deactivates when the IC releases the ground from the relay on circuit 1005 (VT/OG), after time-out. The battery saver relay is integral to the CJB. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - CJB - IC Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8761 F1-F4 Test G: The Courtesy Lamps Do Not Turn On With One Door Open PINPOINT TEST G: THE COURTESY LAMPS DO NOT TURN ON WITH ONE DOOR OPEN Normal Operation On vehicles with remote keyless entry (RKE), the vehicle security module (VSM) monitors the door ajar switch status on circuits 344 (BK/YE), 345 (BK/PK), 346 (BK/WH) and 363 (BK/LB) for a ground supplied through the ajar switches by circuit 57 (BK), indicating a door has been opened. The VSM transmits information over the network to indicate door ajar status. The instrument cluster (IC) then energizes the courtesy lamp circuit, lighting the courtesy lamps. On vehicles without RKE, the 2 front door ajar circuits 344 (BK/YE) and 345 (BK/PK) are monitored directly by the IC. - DTC B2659 (Courtesy Lamp Switch Fault) - is an on-demand DTC that sets when the IC detects a short to ground from the DOME LAMP ON input circuit. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Door ajar switch - VSM (if equipped) - IC Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8762 G1-G2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8763 G2-G5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8764 G6-G8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8765 G8-G10 Test H: An Individual Puddle Lamp Is Inoperative PINPOINT TEST H: AN INDIVIDUAL PUDDLE LAMP IS INOPERATIVE Normal Operation When the instrument cluster (IC) receives the courtesy lamps on request, the IC illuminates the puddle lamps by sending voltage through circuit 53 (BK/LB). Ground for the puddle lamps is provided through circuit 57 (BK). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Exterior mirror Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8766 H1-H3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Page 8767 Courtesy Lamp: Service and Repair PUDDLE LAMP Removal and Installation 1. Release the tab to remove the puddle lamp from the mirror housing. - Disconnect the electrical connector. 2. NOTE: An audible click can be heard when the puddle lamp is fully seated. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Testing and Inspection > Page 8768 Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamps (DRL) Enable Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamps (DRL) Enable Relay > Page 8774 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Relay Daytime Running Lamp Relay: Testing and Inspection Daytime Running Lamps (DRL) Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Relay > Page 8777 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Relay > Page 8778 Daytime Running Lamp Relay: Testing and Inspection Daytime Running Lamps (DRL) Enable Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Relay > Page 8779 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Resistor > Component Information > Diagrams C196 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Resistor > Component Information > Diagrams > Page 8783 Daytime Running Lamp Resistor: Service and Repair DAYTIME RUNNING LAMPS (DRL) RESISTOR Removal and Installation NOTE: Make sure the headlamp switch and the ignition switch are in the OFF position. 1. Remove the radiator side air deflector. - Remove the pin-type retainer. 2. Disconnect the DRL resistor electrical connector. 3. Remove the bolt and the DRL resistor. - To install, tighten to 5 Nm (44 lb-in). 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Left Front View 151-30 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Left Front > Page 8791 View 151-31 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Left Front > Page 8792 View 151-33 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front C526 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8795 C602 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8796 C715 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 8797 C820 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 8798 Door Switch: Service and Repair DOOR AJAR SWITCH Removal and Installation 1. Remove the front or rear door latch. 2. Release the locking tab and remove the door ajar switch. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Locations Exterior Lighting Module: Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 8802 View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 8803 Exterior Lighting Module: Diagrams C3008A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 8804 C3008B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair Fog/Driving Lamp Bulb: Service and Repair FOG LAMP BULB Removal and Installation WARNING: The bulb contains gas under pressure. The bulb may shatter if the glass envelope is scratched or if the bulb is dropped. Handle the bulb only by its base. Avoid touching the glass envelope. Failure to follow these instructions may result in personal injury. NOTE: - The fog lamp bulb should not be removed from the fog lamp until just before a new bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the fog lamp with the bulb removed from the fog lamp. - Make sure the headlamp switch and the ignition switch are in the OFF position. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the electrical connector and remove the fog lamp bulb. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 8812 Fog/Driving Lamp Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations > Page 8817 C2047 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations > Page 8818 Hazard Flasher Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection Hazard Warning Switch: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Page 8822 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair HEADLAMP BULB Removal and Installation WARNING: The bulb contains gas under pressure. The bulb may shatter if the glass envelope is scratched or if the bulb is dropped. Handle the bulb only by its base. Avoid touching the glass envelope. Failure to follow these instructions may result in personal injury. NOTE: - The headlamp bulb should not be removed from the headlamp until just before a new bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the headlamp with the bulb removed from the headlamp. - Make sure that the headlamp switch and the ignition switch are in the OFF position. 1. Remove the headlamp assembly. 2. Rotate the headlamp bulb approximately 1/8 turn counterclockwise and remove the bulb from the headlamp assembly. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations View 151-19 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 8830 Headlamp Dimmer Switch: Diagrams C202A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 8831 C202B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 8832 C202C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 8833 Headlamp Dimmer Switch: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8837 Headlamp Switch: Diagrams C2150A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8838 C2150B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps Headlamp Switch: Testing and Inspection Main Light Switch, Exterior Lamps Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 8841 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 8842 Headlamp Switch: Testing and Inspection Main Light Switch, Interior Lamps Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and Inspection > Page 8843 Headlamp Switch: Service and Repair HEADLAMP SWITCH Removal and Installation 1. Remove the headlamp switch. - Disconnect the headlamp switch electrical connector. 2. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations > Page 8847 High Beam Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations > Page 8848 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations View 151-20 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8860 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8861 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8862 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8863 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8864 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8865 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8866 License Plate Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8867 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8868 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8869 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8870 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8871 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8872 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8873 License Plate Lamp: Connector Views C452 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8874 C462 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8875 License Plate Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 92-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8876 92-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8881 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8882 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8883 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8884 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8885 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8886 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8887 Marker Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8888 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8889 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8890 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8891 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8892 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8893 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8894 Marker Lamp: Connector Views C1127 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8895 C1126 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8896 Marker Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 92-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8897 92-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 8898 Marker Lamp: Service and Repair SIDE LAMP ASSEMBLY - OUTSIDE REAR VIEW MIRROR Aero-Styled Mirror Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 8899 Trailer Tow Mirror Removal and Installation Aero-styled mirror 1. Remove the exterior mirror glass. 2. Remove the 4 screws and the outboard exterior mirror cover. Trailer tow mirror 3. Remove the exterior mirror spotter glass. 4. Remove the outboard exterior mirror cover screw and slightly separate the cover from the mirror assembly. All 5. Using a thin-bladed tool, release the tab by pushing it inward and remove the trailer tow turn lamp. - Disconnect the electrical connector. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions Parking Lamp: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8904 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8905 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8906 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8907 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8908 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8909 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8910 Parking Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8911 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8912 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8913 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8914 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8915 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8916 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8917 Parking Lamp: Connector Views C1023 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8918 C4032 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8919 C4035 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8920 C1043 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8921 Parking Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 92-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8922 92-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Parking Lamp: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the concern is not visually evident, verify the symptom. GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8925 Symptom Chart Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8926 Parking Lamp: Pinpoint Tests Test Q: One Or More Parking, Rear Or License Plate Lamps Is Inoperative PINPOINT TEST Q: ONE OR MORE PARKING, REAR OR LICENSE PLATE LAMPS IS INOPERATIVE Normal Operation The headlamp switch is supplied voltage through circuit 195 (TN/WH). When the headlamp switch is placed in the PARKING LAMPS ON position, the headlamp switch routes voltage to circuit 14 (BN), which then supplies voltage to the exterior lamps. Ground is provided to the bulbs through circuit 57 (BK). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Headlamp switch - Central junction box (CJB) Q1-Q3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8927 Q4-Q5 Test R: The Parking, Rear Or License Plate Lamps Are On Continuously PINPOINT TEST R: THE PARKING, REAR OR LICENSE PLATE LAMPS ARE ON CONTINUOUSLY Normal Operation The headlamp switch is supplied voltage through circuit 195 (TN/WH). When the headlamp switch is placed in the PARKING LAMPS ON position, the headlamp switch supplies voltage to circuit 14 (BN), which then supplies voltage to the exterior lamps. When the vehicle security module (VSM) receives a command to turn the parking lamps on, the VSM provides voltage through circuit 14 (BN) to the parking lamps. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Headlamp switch - VSM Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8928 R1-R3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Page 8929 Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamps (DRL) Enable Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamps (DRL) Enable Relay > Page 8938 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Relay Daytime Running Lamp Relay: Testing and Inspection Daytime Running Lamps (DRL) Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Relay > Page 8941 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Relay > Page 8942 Daytime Running Lamp Relay: Testing and Inspection Daytime Running Lamps (DRL) Enable Relay Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Relay > Page 8943 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations Exterior Lighting Module: Locations View 151-21 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 8947 View 151-25 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 8948 Exterior Lighting Module: Diagrams C3008A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 8949 C3008B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 8953 Fog/Driving Lamp Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 8957 C2047 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 8958 Hazard Flasher Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 8962 High Beam Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 8963 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 8971 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 8972 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 8975 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 8976 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 8977 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 8978 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Reversing Lamp Non-Serviceable Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 8982 C2047 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 8983 Turn Signal Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 8988 C286 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 8989 Ambient Light Sensor: Service and Repair LIGHT SENSOR Removal and Installation 1. Remove the defroster grille panel. - Disconnect the electrical connector. 2. Remove the 2 screws and the light sensor. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Reversing Lamps Switch View 151-12 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Reversing Lamps Switch > Page 8994 Backup Lamp Switch: Locations Digital Transmission Range (DTR) Sensor View 151-10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Reversing Lamps Switch > Page 8995 View 151-11 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Digital Transmission Range (DTR) Sensor C167 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Digital Transmission Range (DTR) Sensor > Page 8998 C169 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations View 151-17 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9002 C278 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9003 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the antilock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9004 Brake Light Switch: Service and Repair STOPLAMP SWITCH Removal and Installation 1. Disconnect the battery. 2. Disconnect the stoplamp switch electrical connector. 3. Remove the retainer. 4. Remove the pin. 5. Remove the stoplamp switch. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Left Front View 151-30 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Left Front > Page 9009 View 151-31 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Left Front > Page 9010 View 151-33 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front C526 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 9013 C602 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 9014 C715 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 9015 C820 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 9016 Door Switch: Service and Repair DOOR AJAR SWITCH Removal and Installation 1. Remove the front or rear door latch. 2. Release the locking tab and remove the door ajar switch. 3. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection Hazard Warning Switch: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 9020 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations View 151-19 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 9024 Headlamp Dimmer Switch: Diagrams C202A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 9025 C202B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 9026 C202C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 9027 Headlamp Dimmer Switch: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations View 151-13 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 9031 Headlamp Switch: Diagrams C2150A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 9032 C2150B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps Headlamp Switch: Testing and Inspection Main Light Switch, Exterior Lamps Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 9035 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 9036 Headlamp Switch: Testing and Inspection Main Light Switch, Interior Lamps Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Page 9037 Headlamp Switch: Service and Repair HEADLAMP SWITCH Removal and Installation 1. Remove the headlamp switch. - Disconnect the headlamp switch electrical connector. 2. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations View 151-20 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations View 151-19 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 9044 Turn Signal Switch: Diagrams C202A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 9045 C202B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 9046 C202C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion Turn Signal Switch: Testing and Inspection Multifunction Switch, Lamp Portion Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 9049 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 9050 Turn Signal Switch: Testing and Inspection Multifunction Switch, Turn Portion Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 9051 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 9052 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch Steering Column Multifunction Switch Removal and Installation 1. Remove the steering wheel. 2. Remove the lower steering column shroud screw. 3. Apply inward pressure to the upper and lower shroud cover seam and remove the lower shroud. 4. Remove the 2 screws and the upper steering column shroud. 5. Remove the screw, release the tab and position the multi-function switch aside. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 9053 6. Disconnect the multi-function switch electrical connector. 7. Remove the multi-function switch. 8. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9058 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9059 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9060 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9061 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9062 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9063 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9064 Tail Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9065 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9066 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9067 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9068 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9069 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9070 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9071 Tail Lamp: Connector Views C4032 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9072 C4035 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9073 Tail Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 92-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9074 92-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9079 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9080 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9081 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9082 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9083 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9084 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9085 Trailer Lamps: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9086 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9087 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9088 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9089 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9090 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9091 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9092 Trailer Lamps: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 95-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9093 95-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Trailer Lamps: Initial Inspection and Diagnostic Overview Principles of Operation PRINCIPLES OF OPERATION The trailer tow stop/turn lamps receive voltage from the vehicle rear stop/turn lamp circuits. When a rear stop/turn lamp is illuminated, voltage is also routed to the trailer tow connector. The trailer tow parking lamps are supplied voltage by the trailer tow parking lamp relay. When the parking lamps are illuminated, voltage is also routed to the trailer tow parking lamp relay coil. When the trailer tow parking lamp relay is energized, voltage is supplied to the trailer tow connector. The trailer tow reversing lamp relay is supplied voltage from the reversing lamp circuit. When the reversing lamps are illuminated, voltage is supplied to the trailer tow connector. The trailer battery charging system supplies battery voltage to the trailer tow connector when the ignition switch is in the RUN position. If equipped, the vehicle also supplies circuitry to support the installation of an aftermarket trailer brake control module (TBCM) (installed by the customer). The vehicle circuitry only supplies voltage, ground, stoplamp switch input and a controlling circuit to the trailer tow connector. The trailer electric brakes themselves are controlled by the aftermarket TBCM and not the vehicle itself. Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Central junction box (CJB) fuse(s): 10 (20A) (trailer tow parking and reversing lamps) - 13 (10A) (trailer tow battery charge relay coil side) - 36 (10A) (trailer tow RH stop/turn) - 42 (10A) (trailer tow LH stop/turn) - 105 (30A) (trailer tow electric brakes) - 106 (30A) (trailer tow battery charge relay switch side) - Bulb(s) - Relay(s) - Wiring, terminals or connectors - Trailer brake control module (TBCM) - Trailer tow connector - Trailer NOTE: When diagnosing the trailer tow lamps, begin by verifying that the vehicle exterior lighting systems are all operating correctly with the trailer disconnected. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the concern is not visually evident, verify the symptom. GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9096 Symptom Chart Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9097 Trailer Lamps: Pinpoint Tests Test Y: The Trailer Lamps Are Inoperative - All PINPOINT TEST Y: THE TRAILER LAMPS ARE INOPERATIVE - ALL Normal Operation Ground for all the trailer tow lamps is supplied to the trailer tow connector through circuit 206 (WH). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer tow connector - Trailer Y1-Y2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9098 Y2 Continued Test Z: The Trailer Lamps Are Inoperative - Stop/Turn PINPOINT TEST Z: THE TRAILER LAMPS ARE INOPERATIVE - STOP/TURN Normal Operation The trailer tow connector receives voltage for the stop/turn lamps through circuits 52 (YE) (LH stop/turn) and 64 (DG) (RH stop/turn), which are fused protected by CJB fuses 42 (10A) and 36 (10A), respectively. Circuits 52 (YE) (LH stop/turn) and 64 (DG) (RH stop/turn) are spliced within the CJB to circuits 9 (LG/OG) and 5 (OG/LB), respectively. When the vehicle stop/turn lamps are illuminated, voltage is also supplied to the trailer tow connector. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow connector - CJB - Trailer Z1-Z2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9099 Z2-Z3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9100 Z4-Z5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9101 Z6-Z7 Tests AA: The Trailer Lamps Are Inoperative - Parking PINPOINT TEST AA: THE TRAILER LAMPS ARE INOPERATIVE - PARKING Normal Operation When the vehicle parking lamps are on, circuit 14 (BN) supplies voltage to the coil side of the trailer tow parking lamp relay. Ground is supplied to the trailer tow parking lamp relay through the central junction box (CJB). When the trailer tow parking lamp relay is energized, voltage is routed from the CJB fuse 10 (20A) to the trailer tow connector through circuit 962 (BN/WH). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow parking lamp relay - Trailer tow connector - CJB - Trailer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9102 AA1-AA2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9103 AA2-AA5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9104 AA5-AA8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9105 AA8 Continued Tests AB: The Trailer Lamps Are Inoperative - Reversing PINPOINT TEST AB: THE TRAILER LAMPS ARE INOPERATIVE - REVERSING Normal Operation When the vehicle reversing lamps are on, circuit 1043 (DG/YE) supplies voltage to the coil side of the trailer tow reversing lamp relay. Ground is supplied to the trailer tow reversing lamp relay through the CJB. When the trailer tow reversing lamp relay is energized, voltage is routed from the CJB fuse 10 (20A) to the trailer tow connector through circuit 140 (BK/PK). The trailer tow reversing lamp relay is integral to the CJB and not removable. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer tow connector - CJB - Trailer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9106 AB1-AB3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9107 AB3-AB4 Tests AC: The Trailer Lamps Are On Continuously PINPOINT TEST AC: THE TRAILER LAMPS ARE ON CONTINUOUSLY Normal Operation The parking lamps are controlled by the trailer tow parking lamp relay. When the trailer tow parking lamp relay is energized, voltage is routed from the central junction box (CJB) to the trailer tow connector through circuit 962 (BN/WH). The reversing lamps are controlled by the trailer tow reversing lamp relay. When the trailer tow reversing lamp relay is energized, voltage is routed from the central junction box (CJB) to the trailer tow connector through circuit 140 (BK/PK). The trailer tow reversing lamp relay is integral to the CJB and not removable. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer tow parking lamp relay - CJB - Trailer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9108 AC1-AC4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9109 AC4-AC6 Tests AD: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly PINPOINT TEST AD: THE TRAILER BATTERY CHARGING IS INOPERATIVE/DOES NOT OPERATE CORRECTLY Normal Operation The trailer battery charging is accomplished through the use of the trailer tow battery charge relay. The trailer tow battery charge relay is supplied voltage and ground through the central junction box (CJB). The trailer tow battery charge relay is energized when the ignitions switch is in the RUN position. When energized, the trailer tow battery charge relay routes voltage from the CJB fuse 106 (30A) to the trailer tow connector through circuit 49 (OG). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow connector - Trailer tow battery charge relay - CJB - Trailer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9110 AD1-AD2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9111 AD2-AD4 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9112 AD4-AD6 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9113 AD6-AD8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9114 AD8-AD9 Tests AE: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly PINPOINT TEST AE: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE/DO NOT OPERATE CORRECTLY Normal Operation The trailer brake control module (TBCM) receives battery voltage from the central junction box (CJB) fuse 105 (30A) through circuit 50 (RD). The trailer brake control module is grounded through circuit 57 (BK). When the brake pedal is applied, the trailer brake control module receives voltage input through circuit 511 (LG) and provides output voltage to the trailer tow connector through circuit 43 (DB). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow connector - CJB - TBCM - Trailer Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9115 AE1-AE3 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9116 AE3-AE5 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9117 AE6-AE8 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9118 AE9-AE10 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Page 9119 Special Tool(s) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 9124 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 9125 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9128 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9129 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9130 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Battery Charge > Page 9131 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Reversing Lamp Non-Serviceable Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front C1023 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 9137 C4032 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 9138 C1043 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 9139 C4035 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations View 151-15 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations > Page 9143 C2047 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations > Page 9144 Turn Signal Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations View 151-19 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 9148 Turn Signal Switch: Diagrams C202A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 9149 C202B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 9150 C202C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion Turn Signal Switch: Testing and Inspection Multifunction Switch, Lamp Portion Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 9153 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 9154 Turn Signal Switch: Testing and Inspection Multifunction Switch, Turn Portion Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 9155 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 9156 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch Steering Column Multifunction Switch Removal and Installation 1. Remove the steering wheel. 2. Remove the lower steering column shroud screw. 3. Apply inward pressure to the upper and lower shroud cover seam and remove the lower shroud. 4. Remove the 2 screws and the upper steering column shroud. 5. Remove the screw, release the tab and position the multi-function switch aside. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 9157 6. Disconnect the multi-function switch electrical connector. 7. Remove the multi-function switch. 8. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp, Left C907 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp, Left > Page 9162 C906 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 9168 Heated Glass Element Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 9169 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 9174 Heated Glass Element Relay: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 9175 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Power Sliding Window Switch, Rear View 151-35 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Power Sliding Window Switch, Rear > Page 9181 Power Window Switch: Locations Window Adjust Switch, Left/Right Rear View 151-32 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Power Sliding Window Switch, Rear > Page 9182 View 151-33 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Power Sliding Window Switch, Rear > Page 9183 View 151-30 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Power Sliding Window Switch, Rear > Page 9184 View 151-31 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch Power Window Switch: Diagrams Master Window Adjust Switch C504A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9187 C504B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9188 C535 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9189 C701 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9190 C604 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9191 C801 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9192 C980 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch Power Window Switch: Testing and Inspection Master Window Adjust Switch Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 9195 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 9196 Power Window Switch: Testing and Inspection Master Window Adjust Switch (Regular Cab) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 9197 Power Window Switch: Testing and Inspection Power Sliding Window Switch, Rear Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 9198 Power Window Switch: Testing and Inspection Power Window Switches, Rear Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 9199 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 9200 Power Window Switch: Testing and Inspection Window Adjust Switch, Passenger Side Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 9201 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Window Control Switch - Front Power Window Switch: Service and Repair Window Control Switch - Front WINDOW CONTROL SWITCH - FRONT Removal and Installation 1. Remove the window control switch bezel. 2. Disconnect the window control switch electrical connectors. 3. Remove the window control switch. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Window Control Switch - Front > Page 9204 Power Window Switch: Service and Repair Window Control Switch - Rear WINDOW CONTROL SWITCH - REAR Removal and Installation 1. Remove the window control switch bezel. 2. Disconnect the window control switch electrical connectors. 3. Remove the window control switch. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Back Window Motor > Component Information > Service and Repair Back Window Motor: Service and Repair WINDOW REGULATOR AND MOTOR - REAR Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Back Window Motor > Component Information > Service and Repair > Page 9210 SuperCrew Material Material Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Back Window Motor > Component Information > Service and Repair > Page 9211 Removal and Installation 1. Remove the rear window glass. 2. Disconnect the rear window glass motor electrical connector. 3. Remove the rear window glass regulator and motor assembly screws. - To install, tighten to 11 Nm (8 lb-ft). 4. Remove the rear window glass regulator and motor assembly from the vehicle. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair WINDOW REGULATOR AND MOTOR - FRONT DOOR Exploded View Removal and Installation 1. Remove the front door trim panel. 2. Remove the front door watershield. 3. Secure the front door window glass in the full UPWARD position with tape. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Page 9215 4. Remove the front door window glass-to-regulator assembly bolts. - Loosen the glass clamp fasteners through the 2 vertical slots in the inner door panel. - To install, tighten to 9 Nm (80 lb-in). 5. Disconnect the front door window electrical connector. 6. Remove the front door window regulator bolts. - To install, tighten to 11 Nm (8 lb-ft). 7. Remove the front door window regulator and motor. 8. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab Rear Door Window Motor: Service and Repair Window Regulator and Motor - Rear Door, SuperCab WINDOW REGULATOR AND MOTOR - REAR DOOR, SUPERCAB Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 9220 SuperCrew Removal and Installation 1. Remove the rear door trim panel. 2. Remove the rear door mounted speaker. 3. Remove the rear door interior moulding. 4. Remove the rear door watershield. 5. Secure the rear door glass in the full upward position with tape. 6. NOTE: Some vehicles may use rivets instead of rear door window glass-to-regulator assembly bolts. Remove the rear door window glass-to-regulator assembly bolts. To install, tighten to 11 Nm (8 lb-ft). 7. Disconnect the rear door window motor electrical connector. 8. Remove the rear door window regulator assembly bolts. - To install, tighten to 11 Nm (8 lb-ft). 9. Remove the rear door window regulator assembly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 9221 10. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 9222 Rear Door Window Motor: Service and Repair Window Regulator and Motor - Rear Door, SuperCrew WINDOW REGULATOR AND MOTOR - REAR DOOR, SUPERCREW Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 9223 SuperCrew Removal and Installation 1. Remove the rear door trim panel. 2. Remove the rear door mounted speaker. 3. Remove the rear door interior moulding. 4. Remove the rear door watershield. 5. Secure the rear door glass in the full upward position with tape. 6. NOTE: Some vehicles may use rivets instead of rear door window glass-to-regulator assembly bolts. Remove the rear door window glass-to-regulator assembly bolts. To install, tighten to 11 Nm (8 lb-ft). 7. Disconnect the rear door window motor electrical connector. 8. Remove the rear door window regulator assembly bolts. - To install, tighten to 11 Nm (8 lb-ft). 9. Remove the rear door window regulator assembly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 9224 10. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 9225 Rear Door Window Motor: Service and Repair Window Regulator and Motor - Rear WINDOW REGULATOR AND MOTOR - REAR Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 9226 SuperCrew Material Material Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 9227 Removal and Installation 1. Remove the rear window glass. 2. Disconnect the rear window glass motor electrical connector. 3. Remove the rear window glass regulator and motor assembly screws. - To install, tighten to 11 Nm (8 lb-ft). 4. Remove the rear window glass regulator and motor assembly from the vehicle. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 9228 Rear Door Window Motor: Service and Repair Window Regulator Motor - Rear WINDOW REGULATOR MOTOR - REAR Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 9229 SuperCrew Removal 1. Remove the rear trim panel pin-type retainers. 2. Remove the rear trim panel. 3. Remove the rear corner trim. For SuperCab vehicles, remove the B-pillar trim panel. For SuperCrew vehicles, remove the C-pillar trim panel. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 9230 4. Disconnect the rear window glass motor electrical connector. 5. Remove the 3 rear window glass regulator and motor assembly screws. 6. Carefully remove the 3 bolts attaching the steel bracket to the plastic cable housing. 7. Hold the plastic cable housing and motor together, place a screwdriver between the drum (located in the cable housing) and the motor housing and pry the motor away from the drum, making sure the drum stays inside the plastic cable housing. Installation 1. Align the motor gear splines onto the drum and press the motor into place, making sure there is correct alignment of the attachment bolt holes. - Install the 3 bolts attaching the steel bracket to the plastic cable housing. 2. Install the rear window glass regulator and motor assembly screws. - Tighten to 11 Nm (8 lb-ft). Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 9231 3. Connect the rear window glass motor electrical connector. 4. Install the rear corner trim. For SuperCab vehicles, install the B-pillar trim panel. For SuperCrew vehicles, install the C-pillar trim panel. 5. Install the rear trim panel 6. Install the rear trim panel pin-type retainers. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Power Sliding Window Switch, Rear View 151-35 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Power Sliding Window Switch, Rear > Page 9236 Power Window Switch: Locations Window Adjust Switch, Left/Right Rear View 151-32 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Power Sliding Window Switch, Rear > Page 9237 View 151-33 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Power Sliding Window Switch, Rear > Page 9238 View 151-30 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Power Sliding Window Switch, Rear > Page 9239 View 151-31 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch Power Window Switch: Diagrams Master Window Adjust Switch C504A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9242 C504B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9243 C535 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9244 C701 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9245 C604 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9246 C801 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 9247 C980 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch Power Window Switch: Testing and Inspection Master Window Adjust Switch Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 9250 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 9251 Power Window Switch: Testing and Inspection Master Window Adjust Switch (Regular Cab) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 9252 Power Window Switch: Testing and Inspection Power Sliding Window Switch, Rear Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 9253 Power Window Switch: Testing and Inspection Power Window Switches, Rear Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 9254 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 9255 Power Window Switch: Testing and Inspection Window Adjust Switch, Passenger Side Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 9256 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Window Control Switch - Front Power Window Switch: Service and Repair Window Control Switch - Front WINDOW CONTROL SWITCH - FRONT Removal and Installation 1. Remove the window control switch bezel. 2. Disconnect the window control switch electrical connectors. 3. Remove the window control switch. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Window Control Switch - Front > Page 9259 Power Window Switch: Service and Repair Window Control Switch - Rear WINDOW CONTROL SWITCH - REAR Removal and Installation 1. Remove the window control switch bezel. 2. Disconnect the window control switch electrical connectors. 3. Remove the window control switch. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair Back Window Glass: Service and Repair WINDOW GLASS - REAR Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 9264 SuperCrew Material Material Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 9265 Removal NOTE: If the rear window glass is being removed to repair a dust/water leak, remove and reinstall the existing rear window glass. All vehicles 1. For Regular and SuperCab vehicles, remove the headliner. For SuperCrew vehicles, lower and position the headliner forward. 2. Remove the rear trim panel pin-type retainers. 3. Remove the rear trim panel. 4. If equipped, disconnect the heated rear backlight connectors. 5. Remove the rear window glass nuts. 6. CAUTION: Use only a plastic windshield setting tool to slide under the seal to separate the foam core butyl from the glass. Once the glass starts to separate from the body, constant hand pressure will break the seal and the glass can be removed. The aid of an assistant will be required to support the glass during this step to prevent damage to the glass frame, body or power sliding window cables, (if equipped). Failure to use a plastic windshield setting tool can damage the body or the glass frame. NOTE: If equipped with power sliding rear window, the glass must be supported in close proximity to the body during the following power sliding rear window removal steps. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 9266 Remove the rear glass from the vehicle. Power sliding rear window 7. Remove the 2 screws from the LH and RH transition blocks. 8. CAUTION: The following substeps are to prevent the cables from popping out of the motor housing. If an existing regulator and motor assembly is to be reused, do not allow the cables to pop out of the motor housing, as they can unwind from the drum. If the cables unwind from the drum, a new regulator and motor assembly will have to be installed. NOTE: LH side shown, RH side similar. Remove the LH cable first, then the RH side cable. Press and hold the transition block away from the centerline of the vehicle. 9. NOTE: LH side shown, RH side similar. Clamp and hold the cable near the transition block. 10. NOTE: LH side shown, RH side similar. Gently pull up the end of the transition block and lift it out of the groove. Do not release the clamp. 11. NOTE: LH side shown, RH side similar. Slowly release the clamp on the cable to gradually unload the tensioning spring on the motor housing. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 9267 12. NOTE: LH side shown, RH side similar. Remove the cable swag from the guide bracket on the sliding rear window. Installation All vehicles 1. NOTE: Remove as much of the foam core butyl as possible from the body and window glass prior to installation. Apply foam core butyl to the window. Overlap the foam core butyl by 25 mm (1 in) at the bottom middle of the rear window glass. Power sliding rear window 2. CAUTION: The following substeps are to prevent the cables from popping out of the motor housing. If an existing regulator and motor assembly is to be reused, do not allow the cables to pop out of the motor housing, as they can unwind from the drum. If the cables unwind from the drum, a new regulator and motor assembly will have to be installed. NOTE: The aid of an assistant will be required to support the glass in close proximity to the body opening during the following power sliding rear window installation steps. - LH side shown, RH side similar. Install the LH cable first, then the RH side cable. Install the cable swag into the guide bracket on the sliding rear window. 3. NOTE: LH side shown, RH side similar. Compress and hold the cable tension spring. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 9268 4. NOTE: - LH side shown, RH side similar. - While holding the LH cable under tension, cycle the window motor to decrease the freeplay on the RH cable. Reducing the freeplay on the RH cable will allow ease of installation of the RH cable. Press the transition block away from the centerline of the vehicle, then snap it into the groove. Release the cable tension spring. 5. NOTE: LH side shown, RH side similar. The transition block is correctly seated when its top edge is +/- 10 mm (0.39 in) above the top of the window opening. 6. Install the LH and RH transition block screws. All vehicles 7. Carefully install the rear window glass into the body opening. 8. Install the rear window glass nuts. - Tighten to 4 Nm (35 lb-in). 9. If equipped, connect the heated rear backlight electrical connectors. 10. Install the rear trim panel. 11. Install the rear trim panel pin-type retainers. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 9269 12. For Regular and SuperCab vehicles, install the headliner. For SuperCrew vehicles, raise and reposition the headliner. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair DOOR GLASS TOP RUN - FRONT Exploded View Removal and Installation 1. Remove the front door trim panel. 2. Remove the front door window glass. 3. Remove the front door glass top run. - Remove the front door glass top run through the top opening of the front door. 4. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear, SuperCab Rear Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Rear, SuperCab DOOR GLASS TOP RUN - REAR, SUPERCAB Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear, SuperCab > Page 9279 SuperCrew Removal and Installation 1. Position the rear door window glass in the full DOWNWARD position. 2. Remove the rear door trim panel. 3. Remove the rear door mounted speaker. 4. Remove the rear door interior moulding. 5. Remove the rear door window glass top run. - Remove the rear door window glass top run through the top opening of the rear door. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear, SuperCab > Page 9280 Rear Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Rear, SuperCrew DOOR GLASS TOP RUN - REAR, SUPERCREW Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear, SuperCab > Page 9281 SuperCrew Removal and Installation 1. Position the rear door window glass in the full DOWNWARD position. 2. Remove the rear door trim panel. 3. Remove the rear door mounted speaker. 4. Remove the rear door interior moulding. 5. Remove the rear door window glass top run. - Remove the rear door window glass top run through the top opening of the rear door. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Back Window Regulator > Component Information > Service and Repair Back Window Regulator: Service and Repair WINDOW REGULATOR AND MOTOR - REAR Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Back Window Regulator > Component Information > Service and Repair > Page 9286 SuperCrew Material Material Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Back Window Regulator > Component Information > Service and Repair > Page 9287 Removal and Installation 1. Remove the rear window glass. 2. Disconnect the rear window glass motor electrical connector. 3. Remove the rear window glass regulator and motor assembly screws. - To install, tighten to 11 Nm (8 lb-ft). 4. Remove the rear window glass regulator and motor assembly from the vehicle. 5. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair WINDOW REGULATOR AND MOTOR - FRONT DOOR Exploded View Removal and Installation 1. Remove the front door trim panel. 2. Remove the front door watershield. 3. Secure the front door window glass in the full UPWARD position with tape. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 9291 4. Remove the front door window glass-to-regulator assembly bolts. - Loosen the glass clamp fasteners through the 2 vertical slots in the inner door panel. - To install, tighten to 9 Nm (80 lb-in). 5. Disconnect the front door window electrical connector. 6. Remove the front door window regulator bolts. - To install, tighten to 11 Nm (8 lb-ft). 7. Remove the front door window regulator and motor. 8. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab Rear Door Window Regulator: Service and Repair Window Regulator and Motor - Rear Door, SuperCab WINDOW REGULATOR AND MOTOR - REAR DOOR, SUPERCAB Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 9296 SuperCrew Removal and Installation 1. Remove the rear door trim panel. 2. Remove the rear door mounted speaker. 3. Remove the rear door interior moulding. 4. Remove the rear door watershield. 5. Secure the rear door glass in the full upward position with tape. 6. NOTE: Some vehicles may use rivets instead of rear door window glass-to-regulator assembly bolts. Remove the rear door window glass-to-regulator assembly bolts. To install, tighten to 11 Nm (8 lb-ft). 7. Disconnect the rear door window motor electrical connector. 8. Remove the rear door window regulator assembly bolts. - To install, tighten to 11 Nm (8 lb-ft). 9. Remove the rear door window regulator assembly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 9297 10. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 9298 Rear Door Window Regulator: Service and Repair Window Regulator and Motor - Rear Door, SuperCrew WINDOW REGULATOR AND MOTOR - REAR DOOR, SUPERCREW Exploded View SuperCab Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 9299 SuperCrew Removal and Installation 1. Remove the rear door trim panel. 2. Remove the rear door mounted speaker. 3. Remove the rear door interior moulding. 4. Remove the rear door watershield. 5. Secure the rear door glass in the full upward position with tape. 6. NOTE: Some vehicles may use rivets instead of rear door window glass-to-regulator assembly bolts. Remove the rear door window glass-to-regulator assembly bolts. To install, tighten to 11 Nm (8 lb-ft). 7. Disconnect the rear door window motor electrical connector. 8. Remove the rear door window regulator assembly bolts. - To install, tighten to 11 Nm (8 lb-ft). 9. Remove the rear door window regulator assembly. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator and Motor - Rear Door, SuperCab > Page 9300 10. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures Windshield: Procedures GLASS RESEAL - WINDSHIELD Material Material 1. Remove the cowl panel grille. 2. Remove the A-pillar trim panels. 3. If equipped, remove the overhead console or dome lamp assembly. 4. Remove the sun visors. 5. Partially lower the front portion of the headliner near the windshield upper opening and block with a suitable material. 6. Clean the edge formed by the existing urethane and the glass on the inside at the top and sides and outside on the bottom of the windshield with glass cleaner. 7. Cut the urethane applicator tip to specification. 8. NOTE: - Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane with less effort and a continuous bead. - Make sure all gaps in the urethane adhesive are smoothed into one continuous bead. Apply urethane adhesive over top of the existing urethane adhesive. Apply the urethane to the top and sides of the windshield from the interior of the vehicle. - Apply the urethane to the bottom of the windshield from the exterior of the vehicle. 9. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks. After the urethane has cured, check the windshield seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary. 10. Position the front portion of the headliner. 11. Install the sun visors. 12. If equipped, install the overhead console or dome lamp assembly. 13. Install the A-pillar trim panels. 14. Install the cowl panel grille. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 9305 Windshield: Removal and Replacement WINDSHIELD GLASS Special Tool(s) Special Tool(s) Material Material Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 9306 Removal 1. Remove the RH and LH side A-pillar trim panels, sun visors, retainers and, if equipped, overhead console. 2. Remove the interior rear view mirror. 3. Partially lower the front portion of the headliner near the windshield upper opening and block with suitable material. 4. Remove the cowl panel grille. 5. NOTE: LH side shown, RH side similar. Press and hold the inside edge of the roof ditch moulding away from the centerline of the vehicle. 6. NOTE: LH side shown, RH side similar. Carefully twist the outside edge of the roof ditch moulding upward to release it from the outside edge of the Y-clip. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 9307 7. NOTE: LH side shown, RH side similar. Push the outside edge of the moulding in toward the center of the vehicle and slide the moulding off the inside edge of the Y-clip. 8. Release the moulding from the remaining 3 Y-clips and remove the moulding. 9. NOTE: LH side shown, RH side similar. Remove the Y-clips. Starting with the bottom Y-clip, work upward toward the roof. Use light pressure to separate the A-pillar track near the Y-clip, then remove the Y-clip. 10. Before cutting the urethane adhesive, remove dirt and other foreign material from the windshield pinchweld area. - Use a clean shop towel or oil-free compressed air. 11. NOTE: Refer to the manufacturer's instructions before using the special tool. Lubricate the urethane adhesive with water to aid the Interior Auto Glass Cut-Out Knife Kit when cutting the urethane adhesive. 12. WARNING: - Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. - Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. CAUTION: To avoid rust formation, use extreme care not to scratch the paint or primer or otherwise damage the pinchweld during glass removal. NOTE: Insert the blade into the special tool so that the flat side is against the glass. This will leave the entire urethane adhesive bead on the pinchweld Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 9308 and allow a dry fit of the replacement windshield glass. - Support the windshield glass to prevent the glass from dropping while cutting the urethane adhesive. Insert the special tool at the upper center of the windshield glass and work toward the bottom corners. 13. Using the special tool, distance the windshield from the body. 14. NOTE: Removing the windshield glass requires more than one technician. Using the special tool, cut the remaining urethane adhesive and remove the window glass and place on a stable work surface. Installation 1. Inspect the glass spacer blocks for damage. If necessary, install new spacer blocks. 2. Dry-fit the windshield glass on the existing urethane adhesive bead on the pinch weld. - Position the windshield glass on the pinch weld. - Center the glass in the opening. - Adjust the windshield spacer blocks as needed for best fit. - Make alignment marks with tape or non-staining grease pencil (preferably at the spacer blocks) on the windshield glass and the body. 3. After the dry-fit alignment, remove the glass from the body opening and place on a stable work surface with the interior side of the glass facing upward. 4. WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s). NOTE: Avoid scratching the pinch weld. For minor scratches or exposed metal on the pinch weld, see the manufacturer's recommendations. Using an appropriate tool, trim the urethane adhesive leaving a 1-2 mm (0.04-0.08 in) base of original equipment urethane on the pinchweld. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 9309 5. Using a clean shop towel, brush or oil-free compressed air, clean the pinch weld area around the existing urethane. Remove any foreign material or water that may have entered during glass removal. 6. If reinstalling the same windshield glass, remove the remaining urethane adhesive from the glass leaving a thin layer to bond with the new urethane bead. 7. Clean the inside of the windshield glass surface with glass cleaner. - Make sure to thoroughly clean the surface of the blackened border area where the urethane adhesive will be applied. 8. CAUTION: Be sure to use the same brand and cure-rate products for the adhesive and primer. Do not mix different brands of urethane and primer. Refer to the Material Chart in this procedure. NOTE: Sika uses the same black primer for the glass and pinch weld area. If installing a new windshield glass, apply urethane glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry. 9. Cut the urethane applicator tip to specification. 10. NOTE: - Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane with less effort and continuous bead. - The windshield glass must be positioned within 10 minutes of applying the urethane adhesive. Apply a uniform bead of urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld. Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead starting and ending at the bottom of the windshield glass near the center. 11. WARNING: Do not drive vehicle until the urethane seal has cured. Follow urethane manufacturer's curing directions. Inadequate or incorrect curing of the urethane seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s). CAUTION: Before positioning the windshield glass, open vehicle windows to prevent the air pressure of closing doors from affecting the Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 9310 adhesive bond. Using the alignment marks made previously, position the windshield glass on the pinch weld. 12. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks. After the urethane has cured, check the windshield glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary. 13. Install the Y-clips. - Each Y-clip snaps into a slot on the bottom of the roof ditch moulding. 14. Install the roof ditch mouldings. 15. Install the cowl panel grille. 16. Raise the front portion of the headliner near the windshield upper opening and install. 17. Install the interior rear view mirror. 18. Install the RH and LH side A-pillar trim panels, sun visors, retainers and, if equipped, overhead console. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations View 151-19 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9316 Windshield Washer Switch: Diagrams C202A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9317 C202B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9318 C202C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9319 Windshield Washer Switch: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9320 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations View 151-19 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9324 Wiper Switch: Diagrams C202A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9325 C202B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9326 C202C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9327 Wiper Switch: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9328 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations View 151-2 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 9332 C137 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair Windshield Washer Pump: Service and Repair WASHER PUMP AND RESERVOIR Exploded View Windshield Wiper System Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Page 9336 Windshield Wiper System Removal and Installation 1. Disconnect the windshield washer pump electrical connector. 2. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTE: To prevent spilling windshield washer fluid, drain fluid from the windshield washer reservoir before removal. Disconnect washer fluid reservoir hose. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Page 9337 3. Remove the 3 washer fluid reservoir bolts. - To install, tighten to 7 Nm (62 lb-in). 4. Remove the washer fluid reservoir. 5. CAUTION: When installing a new windshield washer pump, be careful not to damage the rubber grommet. Remove the windshield washer pump. 6. CAUTION: Do not operate the washer pump prior to filling the windshield washer reservoir. Failure to follow these instructions may result in premature pump failure. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair WASHER PUMP AND RESERVOIR Exploded View Windshield Wiper System Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 9341 Windshield Wiper System Removal and Installation 1. Disconnect the windshield washer pump electrical connector. 2. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTE: To prevent spilling windshield washer fluid, drain fluid from the windshield washer reservoir before removal. Disconnect washer fluid reservoir hose. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 9342 3. Remove the 3 washer fluid reservoir bolts. - To install, tighten to 7 Nm (62 lb-in). 4. Remove the washer fluid reservoir. 5. CAUTION: When installing a new windshield washer pump, be careful not to damage the rubber grommet. Remove the windshield washer pump. 6. CAUTION: Do not operate the washer pump prior to filling the windshield washer reservoir. Failure to follow these instructions may result in premature pump failure. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations View 151-19 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9346 Windshield Washer Switch: Diagrams C202A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9347 C202B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9348 C202C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9349 Windshield Washer Switch: Testing and Inspection Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9350 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair Wiper Arm: Service and Repair WIPER PIVOT ARM Exploded View Windshield Wiper System Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Page 9354 Windshield Wiper System Removal and Installation 1. Remove the wiper pivot arm. 1 Pull up on the pivot arm. 2 Pull out on the retaining tab and remove the pivot arm. 2. NOTE: The windshield wiper motor must be cycled to make sure that it is in the park position. If necessary, adjust the wiper pivot arms. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations View 151-1 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions Wiper Motor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differency in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9360 Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Numbering and Wire Identification (7) Ford Motor Company uses three different circuit numbering conventions: Standard Circuit Numbering System, Global Circuit Numbering System, and Next Global Circuit Numbering System (NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by the wire color. The wire identification consists of a basic color and possibly a stripe, and is determined directly from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4 "Symbols". Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming. Fuse and relay numbering and naming follow the indication of the fuse panel cover. Power Distribution Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9361 Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. Component and Connector Information C904 Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9362 disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Symbols (Part 1) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9363 Symbols (Part 2) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9364 Symbols (Part 3) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9365 Symbols (Part 4) Symbols (Part 5) Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9366 Wiper Motor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminal by pulling each wire at the end of the connector. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9367 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9368 Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9369 Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9370 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9371 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9372 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9373 C125 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 9374 Wiper Motor: Service and Repair WIPER MOTOR Exploded View Windshield Wiper System Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 9375 Windshield Wiper System Removal and Installation 1. Remove the wiper pivot arms. 2. Remove the cowl grille panel. 3. Disconnect the windshield wiper motor electrical connector. 4. Remove the 3 windshield wiper motor assembly bolts. - To install, tighten to 8 Nm (71 lb-in). 5. Remove the windshield wiper motor assembly. 6. To install, reverse the removal procedure. Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations View 151-19 Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9379 Wiper Switch: Diagrams C202A Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9380 C202B Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9381 C202C Ford F 150 2wd Workshop Manual (V8-4.6L (2008)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9382 Wiper Switch: Testing and Inspection