2006 & Older Truck & Diesel SSMs

[Keith Browning]

2006 & Older Truck & Diesel SSMs

 

 

19950 VEHICLE EQUIPPED WITH VAPOR MANAGEMENT VALVE WITH A SERVICE PORT.

SOME VEHICLES ARE EQUIPPED WITH A VMV (VAPOR MANAGEMENT VALVE)WITH AN INTEGRATED SERVICE PORT OR A REMOTE PORT. THE SERVICE PORT IS COVERED WITH A GREEN COLORED CAP THAT IS TETHERED TO THE VALVE. AFTER SERVICING FOR EVAP CONCERNS, BE SURE THE INSIDE OF THE CAP IS CLEAN,THE SEAL IS IN PLACE AND THE CAP RE-SECURED TO THE PORT. (FINGER TIGHTEN ONLY).THE CAP PROVIDES A SEAL FOR THE SERVICE PORT SCHRADER VALVE.

EFFECTIVE DATE: 09/07/2007

 

 

 

19532 2004-2007 F-650/750 - TURN SIGNALS FLASHING RAPIDLY AFTER MODIFICATION - SERVICE TIP

MOST 2004-2007 F-650/750 VEHICLES ARE PRODUCED WITH STANDARD TURN SIGNAL BULBS. IF A BODY BUILDER INSTALLS LIGHT EMITTING DIODE (LED) LAMPS, THE TURN SIGNALS MAY FLASH RAPIDLY WHEN TURNED ON. TO SERVICE, REPLACE THE FACTORY INSTALLED FLASHER WITH A YC3Z-13350-AA FLASHER. THIS MODIFICATION IS NOT COVERED BY WARRANTY, BUT WILL RESOLVE THE CONCERN.

EFFECTIVE DATE: 12/15/2006

 

 

 

19518 2003-2007 F-SUPER DUTY / 2003-2005 EXCURSION / 2004-2007 E-SERIES - 6.0L - NEW IDS EGR TOOL / NO START - 6.0L ENGINE - DIAGNOSTICS FOR FUEL SYSTEM

A NEW EGR SYSTEM DIAGNOSTIC TOOL HAS BEEN DEVELOPED AND IS AVAILABLE ON IDS VERSION 46.7 P6 AND IS LOCATED UNDER POWERTRAIN ; AIR MANAGEMENT SYSTEM ; EGR SYSTEM TEST. THIS TOOL MAY BE USED WITH 6.0L DIESEL EQUIPPED VEHICLES TO DIAGNOSE THE FOLLOWING CONDITIONS: LACK OF POWER, ROUGH IDLE, BLACK SMOKE, WHITE SMOKE, HESITATION, SURGE, P0401, P0402, P0404, P0470, P0478, P2262, P2263, P1335, P0299. IN ADDITION, ONLINE PC/ED DIAGNOSTICS HAVE BEEN UPDATED TO INCLUDE THE NEW TOOL PROCEDURES.PID READING IS A PERCENT OF TANK FULL, SO 50% SHOULD

EFFECTIVE DATE: 12/11/2006

 

 

 

19487 2003-2007 F-SUPER DUTY/2004-2007 E-SERIES/2003-2005 EXCURSION 6.0L - NO CRANK P1705/P0706/P0707 - DIAGNOSE AND SERVICE THE COOLING FAN

SOME VEHICLES EQUIPPED WITH A 6.0L DIT AND TORQSHIFT TRANSMISSION MAY EXHIBIT A NO CRANK/NO START. DTC'S P1705, P0706, P0707 MAY BE PRESENT. IF LOW VOLTAGE (3-4 VOLTS) IS FOUND AT THE TRANSMISSION RANGE POSITION SENSOR PIN 21 CIRCUIT 371 (CIRCUIT 1929 E-SERIES), ELECTRICALLY DISCONNECT THE COOLING FAN CLUTCH AND RETEST THE VOLTAGE. IF THE VOLTAGE NOW READS 12 VOLTS AND THE VEHICLE CRANKS AND STARTS, VERIFY WITH A SHORT TEST DRIVE THAT CODES DO NOT RETURN. DO NOT SERVICE THE TRANSMISSION OR REPLACE THE TRANSMISSION RANGE POSITION SENSOR FOR THIS CONDITION. REFER TO THE APPROPRIATE WIRING DIAGRAM AND WORKSHOP MANUAL SECTION TO DIAGNOSE AND SERVICE THE COOLING FAN.

EFFECTIVE DATE: 11/15/2006

 

 

 

19484 1999-2007 7.3L/6.0L/4.5L DIESEL - CLEAN THE CHARGE AIR COOLER (CAC) SYSTEM AFTER CERTAIN TURBO OR ENGINE FAILURES - SERVICE TIP

ON A 7.3L, 6.0L, OR 4.5L DIESEL EQUIPPED VEHICLE IF THE TURBOCHARGER IS REPLACED FOR AN INTERNAL OIL LEAK OR COMPRESSOR SHAFT FAILURE, THE CHARGE AIR COOLER (CAC) SHOULD BE CHECKED FOR OIL CONTAMINATION AND CONSEQUENTLY CLEANED IF OIL CONTAMINATION IS FOUND. THE CAC SHOULD ALSO BE INSPECTED AND CLEANED OF OIL OR METAL CONTAMINATION AFTER AN ENGINE FAILURE THAT MAY HAVE PUSHED OIL/METAL INTO THE CAC DUE TO EXCESSIVE CRANKCASE PRESSURE. A THOROUGH CLEANING OF THE CAC SYSTEM IS NECESSARY TO PREVENT FURTHER DRIVABILITY OR ENGINE CONCERNS.

EFFECTIVE DATE: 11/14/2006

 

 

 

19420 2003-2007 MULTIPLE VEHICLES 6.0L - DAMAGED/MISSIN OIL FILTER STANDPIPE DUE TO OVERHEATING

SOME 2003-2007 6.0L ENGINE EQUIPPED VEHICLES MAY EXHIBIT A CRANK NO-START AS A RESULT OF ENGINE OVERHEATING. BEFORE ATTEMPTING ANY REPAIR EXAMINE THE OIL FILTER STAND PIPE FOR SIGNS THAT IT IS DAMAGED OR MISSING. IF THE STAND PIPE IS DAMAGED/MISSING, PERFORM NORMAL WORKSHOP MANUAL DIAGNOSTICS TO ISOLATE THE CAUSE OF THE OVERHEAT. ONCE THE ROOT CAUSE OF THE OVERHEAT IS FOUND, PERFORM BASE ENGINE DIAGNOSTICS TO ISOLATE IF ANY OTHER ENGINE DAMAGE HAS OCCURRED. THE OIL FILTER STANDPIPE WILL BE DAMAGED WHEN TEMPERATURE'S EXCEED 350 DEGREES FAHRENHEIT. WITH THESE TEMPERATURES BASE ENGINE OR HIGH PRESSURE OIL SYSTEM DAMAGE CAN OCCUR.

EFFECTIVE DATE: 10/09/2006

 

 

 

19418 2003-2007 MULTIPLE VEHICLES - ENTERTAINMENT SYSTEM - INOPERATIVE HEADPHONES AND REMOTES - SERVICE TIP

SOME 2003-2007 VEHICLES EQUIPPED WITH ENTERTAINMENT SYSTEMS MAY EXPERIENCE INOPERATIVE HEADPHONES AND/OR REMOTES. IT'S VERY IMPORTANT TO TEST THE BATTERIES THAT OPERATE THESE DEVICES AND CONFIRM THEY ARE GOOD BEFORE REPLACING THE SUSPECTED COMPONENT. CONTINUE TO MONITOR OASIS FOR FUTURE UPDATES. PLEASE NOTE: REAR SEAT ENTERTAINMENT COMPONENTS (INCLUDING HEADPHONES, REMOTE ETC) THAT FAIL BECAUSE OF CUSTOMER ABUSE OR NEGLECT, ARE NOT WARRANTABLE.

EFFECTIVE DATE: 10/06/2006

 

 

19417 2003-2007 F-SUPER DUTY/2003-2005 EXCURSION 6.0L - WATCH FOR OIL FLOW FROM THE BASE ENGINE OIL PUMP

SOME 2003-2007 F-SUPER DUTY AND 2003-2005 EXCURSION VEHICLES EQUIPPED WITH A 6.0L DIESEL MAY EXHIBIT LOW BASE ENGINE OIL PRESSURE CAUSED BY A LEAK IN THE HIGH PRESSURE OIL SYSTEM. IF A HIGH PRESSURE SYSTEM LEAK IS SEVERE, THE HIGH PRESSURE PUMP MAY USE A LARGER VOLUME OF OIL THAN THE BASE ENGINE (GEROTOR) PUMP CAN PRODUCE WHILE CRANKING. IF BASE ENGINE OIL PRESSURE IS LOW, REMOVE OIL FILTER, HOLD DOWN THE OIL DRAIN VALVE (LEFT SIDE OF HOUSING) WITH A SCREWDRIVER AND CRANK THE ENGINE WHILE WATCHING FOR OIL FLOW FROM THE BASE ENGINE OIL PUMP. IF FLOW IS PRESENT, USE THE UPDATED DIAGNOSTICS FOR THE HIGH PRESSURE OIL SYSTEM (ELECTRONIC VERSION OF PC/ED, SECTION 4, STEP 10E). IF THERE IS NO FLOW AT THE OIL FILTER HOUSING DIAGNOSE THE BASE ENGINE OIL SYSTEM FIRST (WORKSHOP MANUAL SECTION 303-01C).

EFFECTIVE DATE: 10/06/2006

 

 

 

19389 2003-2007 MULTIPLE VEHICLES 6.0L DIESEL - NO START CONDITION WITH LOW INJECTION CONTROL PRESSURE (ICP) - SERVICE TIPE - DIAGNOSTICS FOR FUEL SYSTEM

SOME AFTERMARKET OIL FILTERS ARE OF THE INCORRECT SIZE AND FIT FOR 6.0L DIESEL EQUIPPED VEHICLES. THIS MAY CAUSE OIL FLOW RESTRICTIONS OR DRAIN BACK, AND MAY RESULT IN A CRANK NO START/HARD START CONDITION WITH LOW OR SLOW TO BUILD INJECTION CONTROL PRESSURE(ICP). WHEN PERFORMING NORMAL DIAGNOSTICS, INSPECT THE OIL FILTER FOR CORRECT FIT AND APPLICATION. INSPECT FOR DAMAGE TO THE OIL FILTER STAND PIPE, CHECK VALVE, AND OIL FILTER HOUSING LID. INSTALL A FILTER THAT FITS PROPERLY, SUCH AS A MOTORCRAFT FL-2016.BRAND OF FUEL. USE OF A NON ALCOHOL

EFFECTIVE DATE: 09/27/2006

 

 

19360 2005-2007 F-SUPER DUTY - INSTALLATION OF UPFITTER SWITCHES ON TRUCKS NOT ORIGINALLY EQUIPPED FROM THE FACTORY

TO INSTALL THE UPFITTER SWITCHES ON A 2005-2007 F-SUPER DUTY, THAT WAS NOT ORIGINALLY EQUIPPED FROM THE FACTORY, ORDER 5C3Z-14A303-AA (WIRE ASY), 5C3Z- 13D730-AAA (SWITCH ASY), AND 5C3Z-2513546-CAA (BOX - UTILITY - LESS HOUSING). THE WIRING HARNESS BOLTS ON, AND THE SWITCH PLUGS INTO IT. THE UTILITY BOX IS ONLY NEEDED IF THE TRUCK IS NOT EQUIPPED WITH A TRAILER BRAKE CONTROLLER. IT MAY BE NECESSARY TO REMOVE THE INSTRUMENT PANEL TO INSTALL THE HARNESS FROM THE BULKHEAD SIDE. REFERENCE Q-117 WHICH CAN BE FOUND AT HTTPS://WWW.FLEET.FORD.COM/TRUCKBBAS/TOPICS/QVMP.HTML FOR ADDITIONAL INFORMATION IF NEEDED.

EFFECTIVE DATE: 09/08/2006

 

 

 

19353 2005-2007 F-SUPER DUTY - UPFITTER SWITCH

2005-2007 F-SUPER DUTY VEHICLES MAY BE EQUIPPED WITH UPFITTER SWITCHES (ACCESSORY SWITCHES) LOCATED ON THE INSTRUMENT PANEL BELOW THE CLIMATE CONTROLS. THIS OPTION INCLUDES FOUR LOW CURRENT ON/OFF SWITCHES THAT CONTROL TWO 10-AMP AND TWO 30-AMP FUSED RELAYS. THE SWITCHES ARE DESIGNED TO ALLOW THE CUSTOMER TO MANUALLY CLOSE A RELAY TO PROVIDE POWER TO ACCESSORIES. REFERENCE Q-117 WHICH CAN BE FOUND AT: HTTPS://WWW.FLEET.FORD.COM/TRUCKBBAS/TOPICS/QVMP.HTML FOR ADDITIONAL INFORMATION IF NEEDED.

EFFECTIVE DATE: 09/06/2006

 

 

 

19335 1999-2007 MULTIPLE VEHICLES - HYDRAULIC BRAKES - GEL-LIKE SUBSTANCE FLOATING ON TOP OF FLUID IN MASTER CYLINDER - SERVICE TIP

SOME 1999 F-800, 1999-2007 F-SUPER DUTY, MOTORHOME CHASSIS, 2000-2005 EXCURSION, 2000-2007 F-650/750, AND 2006-2007 LCF VEHICLES MAY EXHIBIT A CLEAR GEL-LIKE SUBSTANCE IN THE HYDRAULIC BRAKE MASTER CYLINDER RESERVOIR. THIS SUBSTANCE IS A SILICONE BASE LUBRICANT USED DURING ASSEMBLY OF THE MASTER CYLINDER. IT WILL FLOAT ON TOP OF THE BRAKE HYDRAULIC FLUID IN THE MASTER CYLINDER. ADVISE THE CUSTOMER THAT THIS CONDITION IS CONSIDERED NORMAL AND IN NO WAY AFFECTS THE OPERATION OF THE BRAKE SYSTEM. IT DOES NOT REQUIRE ANY SERVICE ACTION.

EFFECTIVE DATE: 08/30/2006

 

 

19257 1999-2007 F-SUPER DUTY - FUEL GAUGE/CLUSTER FAILURES CAUSED BY WELDING - SERVICE TIP

ON 1999-2007 F-SUPER DUTY VEHICLES, BEFORE WELDING ON THE FRAME OR BODY OF A UNIT, DISCONNECT THE BATTERY, INSTRUMENT CLUSTER, ABS MODULE AND THE PCM. JUST DISCONNECTING A BATTERY CABLE IS NOT ENOUGH TO PREVENT DAMAGE TO THESE COMPONENTS. PLEASE REFER QVM BULLETIN Q18 AND Q123 AT HTTPS://WWW.FLEET.FORD.COM/TRUCKBBAS/TOPICS/QVMP.HTML FOR ADDITIONAL INFORMATION.

EFFECTIVE DATE: 07/06/2006

 

 

19254 2005-2007 F-SUPER DUTY - KIT AVAILABLE FOR DEALER INSTALLATION OF TOWCOMMAND SYSTEM

TO INSTALL A TRAILER BRAKE CONTROLLER ON A 2005-2007 F-SUPER DUTY THAT WAS NOT ORIGINALLY EQUIPPED FROM THE FACTORY, ORDER KIT 5C3Z-19H332-AA FOR ALL GAS ENGINE APPLICATIONS; OR ORDER KIT 5C3Z-19H332-BA FOR ALL DIESEL ENGINE APPLICATIONS. FOLLOW THE INSTALLATION PROCEDURES IN THE INSTRUCTION SHEET INCLUDED IN THE KIT. REFERENCE SECTION 206-10 OF THE WORKSHOP MANUAL FOR ADDITIONAL INFORMATION IF NEEDED.

EFFECTIVE DATE: 06/30/2006

 

 

 

19251 2003-2007 F-SUPER DUTY/2003-2005 EXCURSION/2004-2006 E-SERIES 6.0L - PERCEIVED EXCESSIVE FAN NOISE

SOME 6.0L EQUIPPED VEHICLES MAY HAVE PERCEIVED EXCESSIVE FAN NOISE. FAN SPEED, FAN NOISE AND FUEL CONSUMPTION ALL WILL INCREASE FROM DRIVING CONDITIONS THAT INCLUDE TRAILER TOWING, HILL CLIMBING, HEAVY LOADS, HIGH SPEED AND HIGH AMBIENT TEMPERATURE, INDIVIDUALLY OR IN COMBINATION. THE AMOUNT OF FAN NOISE INCREASES AND DECREASES AS ENGINE POWER REQUIREMENTS AND VEHICLE DRIVING CONDITIONS CHANGE AS THE VEHICLE IS DRIVEN. THIS IS TO BE EXPECTED, AND IS NORMAL TO THE OPERATION OF THE VEHICLE, AND SOMETIMES CAN BE MISTAKEN FOR TRANSMISSION DOWNSHIFTING OR SLIPPAGE, LACK OF POWER, OR OTHER ABNORMAL CONDITION, WHICH IT IS NOT. HIGH FAN NOISE MIGHT ALSO BE HEARD WHEN THE ENGINE IS FIRST STARTED, AND SHOULD NORMALLY DECREASE AFTER DRIVING FOR A SHORT TIME.

EFFECTIVE DATE: 06/29/2006

 

 

19235 1996-2007 MULTIPLE VEHICLES - CK TIRE CIRCUMFERENCE & TIRE INFLATION

SOME 4WD VEHICLES EQUIPPED WITH CONTROL TRAC/INTELLIGENT 4WD/ALL WHEEL DRIVE MAY EXHIBIT A SHUDDER ON ACCELERATION, NOISE FROM THE FRONT DRIVELINE AND/OR TRANSFER CASE, AXLE WINDUP AND/OR BINDING WHILE DRIVING AND BEING OPERATED IN THE 4X4/AUTO 4X4 MODE. OTHER 4X4 VEHICLES EQUIPPED WITH (MANUAL OR ELECTRONIC SHIFT) AND A 4X2 MODE MAY ALSO NOT SHIFT ON THE FLY TO 4X4 AUTO OR 4X4 HIGH AT HIGHWAY SPEEDS. THIS MAY BE DUE TO INCORRECT TIRE CIRCUMFERENCE OR IMPROPER TIRE INFLATION PRESSURES. FOUR WHEEL DRIVE AND ALL WHEEL DRIVE VEHICLES REQUIRE THAT ALL FOUR TIRES HAVE THE SAME CIRCUMFERENCE. VERIFY THAT ALL FOUR TIRES HAVE NO MORE THAN 1/4 INCH VARIATION IN CIRCUMFERENCE AND THAT THEY ARE INFLATED TO THE PROPER TIRE PRESSURES(S).

EFFECTIVE DATE: 06/19/2006

 

 

19192 2003-2007 F-SUPER DUTY/2003-2005 EXCURSION - 6.0L - AIR INDUCTION SYSTEM APPEARS TO BE WARPED AND/OR NOT SEALING

SOME 2003-2007 F-SUPER DUTY AND 2003-2005 EXCURSION VEHICLES WITH A 6.0L ENGINE MAY EXHIBIT AN AIR INDUCTION SYSTEM HOUSING THAT APPEARS TO BE WARPED AND/OR NOT SEALING. THE ENGINE SIDE OF THE HOUSING THAT CLAMPS TO THE AIR FILTER HAS A SEAL THAT REQUIRES A HIGH INSERTION FORCE. THIS MAY RESULT IN A WARPED, OR NOT FULLY SEATED, APPEARANCE. GAPS BETWEEN THE HOUSING AND THE FILTER CAN BE AS LARGE AS 0.94 INCHES (24MM) AND STILL MAINTAIN A SEAL. DO NOT REPLACE ANY AIR INDUCTION SYSTEM PARTS IF THERE IS A GAP OF 0.63 INCHES (16MM) OR LESS. IF THE GAP IS GREATER THAN 0.63 INCHES, REMOVE THE FILTER AND REINSTALL. IF THE GAP IS STILL GREATER THAN 0.63 INCHES AFTER RESEATING THE HOUSING TO THE FILTER, REPLACE THE AIR FILTER ELEMENT ONLY.

EFFECTIVE DATE: 05/18/2006

 

 

 

19159 2003-2006 F-SUPER DUTY/2004-2006 E-SERIES/2003-2005 EXCURSION 6.0L - EGR VALVE APPLICATION

THERE ARE TWO DIFFERENT EGR VALVES USED ON 2003-2006 VEHICLES EQUIPPED WITH A 6.0L ENGINE BASED ON VEHICLE BUILD DATE. THE EGR VALVE RETURN SPRING PRELOAD IS DIFFERENT BETWEEN THE TWO EGR VALVES, SO EVEN THOUGH THEY LOOK SIMILAR EXTERNALLY, MAKE SURE THE CORRECT VALVE IS BEING INSTALLED FOR THE VEHICLE YOU ARE CURRENTLY SERVICING. THE PCM CALIBRATION FOR THE VEHICLES USING EACH TYPE OF VALVE IS DIFFERENT, TO ACCOMMODATE THE HIGHER RETURN SPRING PRELOAD. FAILURE TO INSTALL THE CORRECT EGR VALVE CAN CAUSE INCORRECT EGR VALVE POSITION (EGRVP), WHICH MAY LEAD TO REPEAT EGR CODES, SURGING, BUCKING, EXCESSIVE SMOKE AND OTHER ENGINE RELATED DRIVEABILITY SYMPTOMS. THE PART CATALOG DOES CORRECTLY IDENTIFY THE CORRECT EGR VALVE TO USE BY BUILD DATE.

EFFECTIVE DATE: 04/05/2006

 

 

 

19099 2003-2006 F-SUPER DUTY/2003-2005 EXCURSION/2004-2006 E-SERIES - 6.0L - P0404 SERVICE TIP

SOME 2003-2006 F-SUPER DUTY, 2003-2005 EXCURSION, AND 2004-2006 E-SERIES VEHICLES EQUIPPED WITH A 6.0L DIESEL ENGINE MAY SET A P0404 DTC IF THE BATTERY IS DISCONNECTED, KAM IS RESET, THE EGR VALVE IS REPLACED, OR IF THE EGR VALVE IS REMOVED AND REINSTALLED. PERFORM THE WDS/IDS KOEO ON DEMAND SELF TEST TO LEARN EGR VALVE CLOSED POSITION IF ANY OF THE LISTED CONDITIONS EXIST.

EFFECTIVE DATE: 02/22/2006

 

 

 

19098 MULTIPLE VEHICLES - SULFUR BUILD-UP ON FUEL LEVEL SENSOR - ADD "CHEVRON TECHRON PLUS FUEL SYSTEM CLEANER" TO FUEL AND FILL WITH FRESH FUEL

GASOLINE OR DIESEL VEHICLES MAY EXHIBIT ERRATIC FUEL GAUGE READINGS, ILLUMINATED MIL, AND DTC P0463, P2068 AND/OR B1202, B2627 MAY BE PRESENT. THIS CONDITION MAY OCCUR DUE TO SULFUR CONTAMINATION FOUND IN SOME LOCAL FUELS WHICH MAY CAUSE TEMPORARY CONTAMINATION OF THE FUEL SENDER CARD. BEFORE REPLACING ANY COMPONENT, CLEAR DTC'S, DRAIN FUEL TANK (IF FACILITIES PERMIT), ADD TECHRON CONCENTRATE PLUS FUEL SYSTEM CLEANER AND ADVISE CUSTOMER TO USE AN ALTERNATE BRAND OF FUEL. THE CONDITION SHOULD CORRECT ITSELF IN A FEW MILES. ADVISE CUSTOMERS TO UTILIZE THE TRIP ODOMETER TO MONITOR FUEL CONSUMPTION. REPLACEMENT OF COMPONENTS OR PCM REPROGRAMMING MAY NOT FIX THE CONCERN. IF CONCERN PERSISTS PERFORM NORMAL DIAGNOSIS AND REPAIR. OBTAIN THE NEW TECHRON PLUS FUEL ADDITIVE LOCALLY FROM YOUR LOCAL AUTOMOTIVE CHEMICAL SUPPLY SOURCE OR AUTO PARTS STORE.

EFFECTIVE DATE: 02/22/2006

 

 

 

19017 MULTIPLE VEHICLES - HO2S AND CATALYST MONITOR SENSORS - SERVICE TIP

HO2S SENSORS(HEGO)AND DOWNSTREAM CATALYST MONITOR SENSORS (CMS) ARE NOT THE CAUSE OF DTCS P0171,P0172,P0174,P0175, P0420,OR P0430. DO NOT REPLACE THE HO2S SENSORS OR MONITORS FOR THESE CODES UNLESS VERIFIED THROUGH PINPOINT DIAGNOSTIC TESTS FOR OTHER EXISTING DTCS, AS OUTLINED IN THE PC/ED SERVICE MANUAL. WHEN THE CATALYST OR ANY EXHAUST COMPONENT REPLACEMENT IS NECESSARY, USE CARE AS TO NOT PHYSICALLY DAMAGE ANY SENSORS ATTACHED TO THE SYSTEM.

EFFECTIVE DATE: 01/23/2006

 

 

 

18994 2005-2006 F-SUPER DUTY AND 2005 EXCURSION - BLOCK HEATER CORD MISSING

THE BLOCK HEATER FOR THE 6.0L ENGINE IS NOW OPTIONAL ON 2005-2006 F-SUPER DUTY AND 2005 EXCURSION VEHICLES (ORDER CODE 41H). THE BLOCK HEATER IS STILL STANDARD IF VEHICLES ARE ORDERED IN CANADA, OR IN THE STATES OF AK, CO, IA, ME, MN, MT, ND, SD, WI, AND WY. ALL 6.0L ENGINES WILL HAVE THE HEATER ELEMENT INSTALLED IN THE ENGINE, THE ATTACHING CORD IS THE OPTIONAL COMPONENT. IF EQUIPPED, THE CORD IS STOWED IN THE FRONT BUMPER OPENING. DO NOT INSTALL BLOCK HEATER CORDS UNDER WARRANTY. IF THE CORD IS MISSING, AND THE VEHICLE WAS ORDERED IN CANADA, ONE OF THE STATES ABOVE, OR WITH ORDER CODE 41H, A MISBUILT UNIT CLAIM SHOULD BE FILED.

EFFECTIVE DATE: 12/21/2005

 

 

 

18926 2005 EXCURSION/2005-2006 E-SERIES/F-SUPER DUTY - 6.0L - NO ICP FROM INJECTOR SEAL/SPRING CLIP

SOME 2005 EXCURSION AND 2005-2006 F-SUPER DUTY, AND E-SERIES VEHICLES EQUIPPED WITH A 6.0L DIESEL MAY EXHIBIT A HARD START, OR NO START CONDITION WITH LOW OR NO INJECTION CONTROL PRESSURE (ICP). DURING NORMAL HIGH PRESSURE SYSTEM DIAGNOSIS, BE SURE TO INSPECT WHERE THE HIGH PRESSURE OIL RAIL SEATS INTO THE TOP OF EACH FUEL INJECTOR FOR A DAMAGED OR MISSING SEAL RING AND/OR SPRING CLIP. IF COMPONENTS ARE MISSING, THEY MUST BE LOCATED OR ENGINE DAMAGE WILL RESULT. THE MOST LIKELY LOCATIONS ARE IN THE TOP OF THE HEAD, IN THE OIL PAN, OR IN THE PICK UP SCREEN. IF THE COMPONENTS ARE NOT FOUND, INSPECT THE LOW PRESSURE OIL PUMP AND REGULATOR.

EFFECTIVE DATE: 11/07/2005

 

 

 

18778 MULTIPLE VEHICLES - ENGINE INSTALLATION INSTRUCTIONS

WHEN REPAIRING A VEHICLE USING A FORD REMANUFACTURED (FR) OR MOTORCRAFT LONG BLOCK OR SHORT BLOCK, PLEASE REVIEW AND FOLLOW THE ENGINE INSTALLATION INSTRUCTIONS THAT COME WITH EACH LONG OR SHORT BLOCK. FOLLOWING THESE INSTRUCTIONS WILL HELP PREVENT REPEAT REPAIRS AND ENSURE CUSTOMER SATISFACTION.

EFFECTIVE DATE: 08/12/2005

 

 

 

18578 2003-2005 MULTIPLE VEHICLES - DTC P0191, P0171 AND/OR P0174

FOR 2003-2005 MULTIPLE VEHICLE LINES WHICH USE ELECTRONIC RETURNLESS FUEL SYSTEM {ERFS}, THE APPEARANCE OF SELF TEST CONTINUOUS MEMORY DIAGNOSTIC TROUBLE CODE P0191 (FRP CKT PERFORMANCE) DOES NOT SPECIFICALLY INDICATE A FUEL RAIL PRESSURE SENSOR OR FUEL SYSTEM CIRCUIT FAILURE. THE FUEL RAIL SENSOR SHOULD NOT BE REPLACED BASED ONLY UPON THE APPEARANCE OF THIS DTC ALONE. FOLLOW THE REVISED ON-LINE PC/ED PINPOINT TESTING FOR DTC P0191 TO DIAGNOSE. ALSO, THE APPEARANCE OF DTC'S P0171 (HO2S11 LEAN PRT THRT) AND/OR P0174 (HO2S21 LEAN PRT THRT) MAY BE THE RESULT OF LOW FUEL PRESSURE. DO NOT REPLACE ANY COMPONENTS OR REPROGRAM THE PCM UNLESS PINPOINT TESTING OR OTHER PUBLISHED SERVICE PROCEDURES SPECIFICALLY PROVIDES THAT REPAIR ACTION.

EFFECTIVE DATE: 04/25/2005

 

 

 

18503 2003-2005 F-SUPER DUTY/EXCURSION AND 2004-2005 E-SERIES - 6.0L INJECTOR REPLACEMENT - SERVICE TIP

ON ALL 6.0L DIESEL ENGINES ANYTIME AN INJECTOR IS LOOSENED, REMOVED, OR REPLACED, THE COPPER WASHER AND INJECTOR O-RINGS MUST BE REPLACED. WHEN REPLACING AN INJECTOR, MAKE SURE THE OLD COPPER WASHER HAS BEEN REMOVED FROM THE INJECTOR CUP.

EFFECTIVE DATE: 03/23/2005

 

 

 

18465 1997-2005 MULTIPLE VEHICLES - INTERMITTENT MIL ON WITH DTC P0460 - SERVICE TIP

SOME 1997-2005 VEHICLES MAY EXHIBIT AN INTERMITTENT MALFUNCTION INDICATOR LAMP (MIL) ON WITH DTC P0460 (FUEL LEVEL SENSOR CIRCUIT MALFUNCTION). THIS CONDITION MAY BE CAUSED BY AN IMPROPERLY INSTALLED REMOTE START SYSTEM, AFFECTING THE FLUID LEVEL INPUT (FLI) INFORMATION TO THE PCM. THE CONDITION MAY BE DIFFICULT TO DUPLICATE. TO SERVICE, CHECK FOR AN IMPROPERLY INSTALLED FORD OR AFTERMARKET REMOTE STARTER SYSTEM. THE INSTRUMENT CLUSTER OR HEC MUST HAVE POWER TO ALL 'HOT IN RUN' CIRCUITS FOR THE FUEL GAUGE CIRCUIT TO PROPERLY RELAY FLI INFORMATION TO THE PCM (EITHER BY NETWORK COMMUNICATION OR A DIRECT HARDWIRE CIRCUIT).

EFFECTIVE DATE: 03/11/2005

 

 

 

18217 MULTIPLE VEHICLES - FUEL LEVEL INDICATION CONCERNS - SERVICE TIPK, EXCESSIVE

SOME 2000-2005 SUPER DUTY F-SERIES/F-150/EXCURSION/EXPEDITION/NAVIGATOR, 2001-2005 ESCAPE, 2002-2003 BLACKWOOD, 2002-2005 EXPLORER 4DR/MOUNTAINEER, AND 2003-2005 AVIATOR VEHICLES MAY EXHIBIT FUEL LEVEL INDICATOR CONCERNS. PRIOR TO STARTING NORMAL DIAGNOSTICS, PERFORM THE FOLLOWING QUICK TEST: 1) DISCONNECT THE BATTERY(S) FOR ONE MINUTE AND RECONNECT. 2) USE THE NGS DIAGNOSTIC (RED) CARD TO VIEW THE 'FUELLVL PID' IN THE HEC/ICM TO CHECK THE FUEL SIGNAL TO THE INSTRUMENT CLUSTER. THE PID READING IS A PERCENT OF TANK FULL, SO 50% SHOULD HAVE A FUEL GAUGE INDICATION OF ABOUT 1/2 TANK. THE PID VALUE RESPONDS INSTANTLY TO FUEL SLOSH AND VEHICLE TILT, BUT THE FUEL GAUGE RESPONDS MORE SLOWLY TO COMPENSATE FOR SLOSH. IF AN ISSUE IS CONFIRMED, PROCEED WITH NORMAL DIAGNOSTICS FOR THE SENDER OR CLUSTER BASED ON THE RESULTS.AT LEAST ONE BOTTLE.

EFFECTIVE DATE: 10/08/2004

 

 

 

18107 1994-2003 MULTIPLE VEHICLES WITH 7.3L DIT - INJECTOR PERFORMANCE TEST PROCEDURE

THERE IS A NEW PROCEDURE AVAILABLE FOR TESTING INJECTORS ON ALL 7.3L DI TURBO EQUIPPED VEHICLES. A NEW 7.3L DIESEL FUEL INJECTOR TEST STAND, TOOL NUMBER 310-141, HAS BEEN SHIPPED TO ALL FORD DEALERSHIPS. INSTRUCTIONS FOR USING THIS TOOL ARE IN ELECTRONIC VERSIONS OF THE 2001-2003 PC/ED MANUAL (JULY 2004 OR LATER), SECTION 4A. THE TOOL WILL DIAGNOSE INTERNAL INJECTOR SEALING FAILURES, BUT NOT INJECTOR CONCERNS CAUSED BY CONTAMINATION FROM FUEL QUALITY OR LACK OF OIL MAINTENANCE. INJECTOR REMOVAL IS REQUIRED SO ALL OTHER INJECTOR ELECTRICAL AND BASE ENGINE DIAGNOSIS MUST BE PERFORMED PRIOR TO TESTING WITH THE NEW TOOL. REFER TO APPROPRIATE MY PC/ED FOR ALL INITIAL DIAGNOSIS. IF AN INJECTOR IS SUSPECTED AFTER INITIAL DIAGNOSIS, REFER TO A 2001-2003 PC/ED FOR THE TOOL USAGE PROCEDURE.

EFFECTIVE DATE: 08/30/2004

 

 

 

17810 - 1998-2004 CROWN VICTORIA/GRAND MARQUIS/TOWN CAR - TRANSMISSION FAILURE AND REPAIR - SERVICE TIP

SOME 1998-2004 CROWN VICTORIA, GRAND MARQUIS AND TOWN CAR VEHICLES MAY EXHIBIT A TRANSMISSION FAILURE WHERE THERE IS A LARGE AMOUNT OF METAL OR DEBRIS IN THE PAN. WHEN THE TRANSMISSION IS REPAIRED OR REPLACED PERFORM THE FOLLOWING TO AVOID REPEAT REPAIRS: -FLUSH ALL TRANS LINES USING THE PROCEDURE OUTLINED IN SECTION 307-01 OF THE WORKSHOP MANUAL. -REPLACE THE OIL TO AIR (OTA) COOLER (IF EQUIPPED) AS IT CANNOT BE FLUSHED. -INSTALL AN IN LINE-FILTER KIT (XC3Z-7B155-CA) TO CATCH ANY EXTRA DEBRIS THAT MAY HAVE REMAINED IN THE LINES AFTER FLUSHING. -ALWAYS REPLACE THE TRANSMISSION FLUID FILTER.

 

 

 

17683 - 2003-2004 SUPER DUTY F-SERIES/EXCURSION AND 2004 ECONOLINE 6.0L - ENGINE OIL LEAKS AT LOWER CRANKCASE

SOME 2003-2004 SUPER DUTY F-SERIES/EXCURSION AND 2004 ECONOLINE VEHICLES WITH A 6.0L ENGINE MAY EXHIBIT AN OIL LEAK THAT APPEARS TO BE COMING FROM THE LOWER CRANKCASE (BED PLATE). CLEAN THE SUSPECT AREA AND ADD DYE TO DETERMINE LEAK SOURCE. INSPECT FOR CAM AND/OR CRANK SENSOR O-RING LEAKAGE THAT RESULTS IN OIL TRAVEL GIVING THE APPEARANCE OF A LOWER CRANKCASE LEAK. CAM AND CRANK SENSOR O-RINGS ARE AVAILABLE FOR SERVICE (CMP: 3C3Z-9N693-HA [OUTER] 3C3Z- 9N693-JA [iNNER] / CPK: 3C3Z-9C064-DA). LOWER CRANKCASE LEAKS CAN BE CAUSED BY REMOVAL OF THE FRONT OR REAR COVER WITHOUT CUTTING THE "T" JOINT AREAS. WHEN SERVICING THE FRONT COVER APPLY A BEAD OF RTV SEALANT AT THE CRANKCASE TO LOWER CRANKCASE SEAM. WHEN SERVICING THE REAR ENGINE COVER APPLY A BEAD OF SEALANT AT THE CRANKCASE TO LOWER CRANKCASE SEAM AND THE OIL PUMP COVER JOINT.

EFFECTIVE DATE: 04/01/2004 supercedes to 3c3z-9229-b for cmp rins

 

 

 

17643 - 2003-2004 SUPER DUTY F-SERIES/EXCURSION WITH TORQSHIFT - HARSH/SLIPPING ENGAGEMENTS, UPSHIFTS AND/OR DOWNSHIFTS - ADAPTIVE SHIFT STRATEGY

WHEN THE BATTERY IS DISCONNECTED ON 2003-2004 SUPER DUTY F-SERIES AND EXCURSION VEHICLES WITH A TORQSHIFT TRANSMISSION, THE ADAPTIVE SHIFT STRATEGY MAY BE LOST, TEMPORARILY RESULTING IN HARSH/SLIPPING ENGAGEMENTS, UPSHIFTS AND/OR DOWNSHIFTS. THIS CONDITION IS NORMAL AND MAY ALSO OCCUR ON NEW VEHICLES THAT HAVE JUST ARRIVED FROM THE PLANT. TO ACCELERATE ADAPTIVE LEARNING: WARM ENGINE AND TRANSMISSION TO NORMAL OPERATING TEMPERATURE; PERFORM 3 SERIES OF UPSHIFTS AT LIGHT, MEDIUM, AND HEAVY THROTTLE; PERFORM 3 SETS OF ENGAGEMENTS (N-R, N-D, D-R, AND R-D) WITH FOOT FIRMLY ON BRAKE, WAITING 3 SECONDS BETWEEN EACH EVENT; THIS PROCEDURE IS TO BE PERFORMED TWO TIMES, ONCE WITH AND ONCE WITHOUT TOW/HAUL ACTIVATED.

 

 

 

17605 - 6.0 Liter overheats with plow- 2003-2004 SUPER DUTY F-SERIES 6.0L - ENGINE OVERHEATING WITH SNOW PLOW INSTALLED

SOME 2003-2004 SUPER DUTY F-SERIES EQUIPPED WITH A 6.0L DIESEL AND SNOW PLOW PACKAGE (86M) MAY EXHIBIT THE ENGINE OVERHEATING DURING NORMAL HIGHWAY DRIVING DUE TO THE SNOW PLOW BLADE DISRUPTING AIRFLOW, CAUSING THE ENGINE COOLING FAN TO STOP TURNING OR SPIN IN REVERSE. INSTALL REVISED CLUTCH FAN 4C3Z-8A616-SA (ONLY FOR SNOW PLOW APPLICATIONS). SEE WORKSHOP MANUAL SECTION 303-03 FOR REMOVAL AND INSTALLATION. NOTE: INSTALLATION OF THIS COMPONENT MAY RESULT IN REDUCED FUEL ECONOMY. NOTE: PRIOR TO THE AVAILABILITY OF THE REVISED CLUTCH FAN, A JUMPER MAY HAVE BEEN INSTALLED BETWEEN THE FAN CONNECTOR ON THE RADIATOR SHROUD AND ITS NORMAL CONNECTION TO THE ENGINE HARNESS, ALLOWING THE FAN TO OPERATE CONTINUOUSLY. THIS JUMPER MUST BE REMOVED AND DISCARDED TO RETURN FAN OPERATION TO NORMAL AND PREVENT POSSIBLE DTC P0480 FROM OCCURRING.

 

 

 

17573 - 1994-2004 VARIOUS VEHICLES EQUIPPED WITH 6.0L/7.3L - INJECTION CONTROL PRESSURE (ICP) AND EXHAUST BACK PRESSURE (EBP) WIRING CONNECTOR SERVICE KIT

SOME 1994-2004 VEHICLES EQUIPPED WITH A 7.3L OR 6.0L DIESEL ENGINE MAY EXHIBIT DRIVEABILITY CONDITIONS CAUSED BY THE ICP AND EBP WIRING CONNECTORS. IF A POOR CONNECTION EXISTS, THE ENGINE CONTROL SYSTEM MAY ENTER A DEFAULT MODE AND SET EITHER DIAGNOSTIC TROUBLE CODE P1280 (7.3L ICP), P2285 (6.0L ICP) OR P0472 (6.0L AND 7.3L EBP). THESE DTC'S TYPICALLY IDENTIFY AN OPEN CIRCUIT. IF ANY OF THESE CODES IS PRESENT, CLEAR THE CODE AND WIGGLE TEST THE CONNECTOR. IF THE WIGGLE TEST DUPLICATES THE ISSUE, EITHER CONNECTOR MAY BE REPLACED WITH SERVICE KIT 3C3Z-12224-BA (1994-1996 7.3L) OR 3C3Z-12224-AA (1997-2003 7.3L AND 2003-2004 6.0L). THE KIT CONTAINS A CONNECTOR WITH PIGTAIL, 3 BUTT SPLICES, 3 SHRINK TUBES AND INSTRUCTIONS.

 

 

 

17571 1994-2004 MULTIPLE VEHICLES WITH 7.3L OR 6.0L - MIL ON WITH DTC P0603 OR P0605

SOME 1994-2004 SUPER DUTY F-SERIES, ECONOLINE AND 2000-2004 EXCURSION VEHICLES EQUIPPED WITH 7.3L OR 6.0L DIESEL ENGINES MAY EXHIBIT DIAGNOSTIC TROUBLE CODES P0603 (POWERTRAIN CONTROL MODULE KEEP ALIVE MEMORY ERROR) OR P0605 (POWERTRAIN CONTROL MODULE READ ONLY MEMORY ERROR). DTC P0603 MAY BE GENERATED IF THE PCM, OR BOTH BATTERIES, ARE DISCONNECTED. TO SERVICE DTC P0603 ON 7.3L EQUIPPED VEHICLES, FIRST RUN THE ENGINE FOR MORE THAN 30 SECONDS, THEN CLEAR ALL DTC'S. FOR 6.0L EQUIPPED VEHICLES, REPROGRAM THE PCM TO THE LATEST CALIBRATION LEVEL USING WDS RELEASE B28.9 OR HIGHER. TO SERVICE DTC P0605 ON EITHER 7.3L OR 6.0L EQUIPPED VEHICLES, REPROGRAM THE PCM TO THE LATEST CALIBRATION LEVEL USING WDS RELEASE B28.9 OR HIGHER. CALIBRATION UPDATES CAN ALSO BE OBTAINED AT www.MOTORCRAFT.COM.R PERFORMANCE AFTER AT LEAST ONE BOTTLE.

EFFECTIVE DATE: 02/20/2004

 

 

 

17351 - 2003-2004 SUPER DUTY F-SERIES/EXCURSION WITH TORQSHIFT - HARSH DISENGAGEMENT WHEN SHIFTING FROM REVERSE TO PARK

SOME 2003-2004 SUPER DUTY F-SERIES AND EXCURSION VEHICLES BUILT BEFORE 11/14/2003 WITH A 6.0L DIESEL ENGINE AND TORQSHIFT AUTOMATIC TRANSMISSION MAY EXHIBIT A HARSH DISENGAGEMENT WHEN SHIFTING FROM REVERSE TO PARK. A CLUNK MAY ALSO BE HEARD DURING THIS DISENGAGEMENT. TO CORRECT THIS CONDITION, REPLACE THE ORIGINAL SOLENOID BODY MANUAL VALVE WITH A REDESIGNED PART 4C3Z-7D376-AA. TO PERFORM THIS REPAIR, FIRST REMOVE THE SOLENOID BODY ASSEMBLY. REPLACE THE MANUAL VALVE WITH THE REDESIGNED VALVE, INSERTING IT PLUGGED-END FIRST INTO THE SOLENOID BODY. USE A NEW SOLENOID BODY-TO-CASE GASKET (3C3Z-7C155-DA) DURING REINSTALLATION, CLEAN AND REUSE THE BOTTOM PAN GASKET, AND TOP OFF WITH MERCON SP TRANSMISSION FLUID.

 

 

 

17339 1995-2004 OBDII EQUIPPED VEHICLES - DTC P0171 AND/OR P0174

SOME 1995-2004 OBDII EQUIPPED VEHICLES MAY EXHIBIT A MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODE (DTC) P0171 (SYSTEM TOO LEAN - BANK 1) AND/OR P0174 (SYSTEM TOO LEAN - BANK 2) DUE TO A VACUUM LEAK IN THE PCV SYSTEM. TO SERVICE, INSPECT THE PCV SYSTEM INCLUDING ALL RUBBER COMPONENTS, ELBOW CONNECTORS AT INTAKE MANIFOLD PORTS AND THE PCV VALVE ITSELF FOR DETERIORATION OR CHAFING. SQUEEZING THE RUBBER COMPONENTS MAY REVEAL DETERIORATION AND CRACKS NEAR BRITTLE OR SOFT SPOTS. DETERIORATION MAY CAUSE HOSES TO COLLAPSE AND NOT RETURN TO THEIR NATURAL FORM. REPLACE ONLY THE AFFECTED PCV COMPONENTS. REPLACING THE PCM, MAF SENSOR OR HEGO(S) WILL NOT REPAIR LEAN CODES CAUSED BY LEAKING PCV COMPONENTS.

EFFECTIVE DATE: 11/12/2003

 

 

 

17268 1994-2003 MULTIPLE VEHICLES WITH 7.3L DIT - IDLE ROLL/LOPE ON COLD START

SOME 1994-2003 SUPER DUTY F-SERIES/E-SERIES AND 2000-2003 EXCURSIONS EQUIPPED WITH THE 7.3L DIT ENGINE MAY EXHIBIT AN IDLE ROLL/LOPE ON COLD START THAT LASTS UP TO ONE MINUTE. THIS CONDITION IS CONSIDERED A CHARACTERISTIC OF THE 7.3L. THE FOLLOWING STEPS CAN BE TAKEN BY THE CUSTOMER TO REDUCE THE LIKELIHOOD OF THIS CONDITION: CHANGE TO A 10W-30 OIL (XO-10W-30-QSD) LABELED CI-4 OR CH-4; PLUG IN THE BLOCK HEATER WHEN OUTSIDE TEMPERATURES ARE GOING TO BE BELOW 30F (-1C); LEAVE THE IGNITION IN THE RUN POSITION FOR A FULL 2 MINUTES SO THE GLOW PLUGS CAN FULLY HEAT THE CYLINDERS BEFORE CRANKING THE ENGINE.

EFFECTIVE DATE: 10/13/2003

 

 

 

 

17076 - 2003-2004 SUPER DUTY/EXCURSION 6.0L - WATER IN FUEL LIGHT ILLUMINATED

SOME 2003-2004 SUPER DUTY/EXCURSION VEHICLES EQUIPPED WITH A 6.0L POWERSTROKE MAY EXHIBIT A WATER IN FUEL (WIF) LIGHT ON, WHICH DOES NOT TURN OFF AFTER WATER HAS BEEN DRAINED FROM THE HORIZONTAL FUEL CONDITIONING MODULE (HFCM). THIS MAY BE DUE TO CORROSION/SEDIMENT BUILD UP IN THE WATER RESERVOIR. TO SERVICE, FIRST VERIFY ELECTRICAL CONNECTIONS. IF ELECTRICAL CONNECTIONS ARE OKAY, REMOVE THE FUEL MANIFOLD FROM THE HFCM. INSPECT/CLEAN DEBRIS (MAX 25 PSI AIR) FROM THE WATER RESERVOIR IN HFCM HOUSING. INSTALL NEW FUEL MANIFOLD PN 3C3Z-9B249-AB AND REASSEMBLE THE FUEL MANIFOLD TO THE HFCM. REFER TO WORKSHOP MANUAL SECTION 310-01 FOR HFCM DISASSEMBLY AND ASSEMBLY PROCEDURES.

 

 

 

16966 - ICP & EBP WIRING CONNECTOR SERVICE KIT

1994-2003 VARIOUS VEHICLES EQUIPPED WITH 6.0L/7.3L - INJECTION CONTROL PRESSURE (ICP) AND EXHAUST BACK PRESSURE (EBP) WIRING CONNECTOR SERVICE KIT, SOME 1994-2003 VEHICLES EQUIPPED WITH A 7.3L OR 2003 MY 6.0L DI TURBO ENGINE MAY EXHIBIT DRIVEABILITY CONDITIONS CAUSED BY THE ICP AND EBP WIRING CONNECTORS. IF A POOR CONNECTION EXISTS, THE ENGINE CONTROL SYSTEM MAY ENTER DEFAULT AND SET EITHER A P1280 (7.3L - ICP), P2285 (6.0L - ICP) OR A P0472 (6.0L AND 7.3L - EBP) DTC. THESE DTC'S TYPICALLY IDENTIFY AN OPEN CIRCUIT. IF EITHER OF THESE CODES IS PRESENT, CLEAR THE CODE AND WIGGLE TEST THE CONNECTOR. IF THE WIGGLE TEST IDENTIFIES THE CONDITION, EITHER CONNECTOR MAY BE REPLACED WITH SERVICE KIT FOR 1994-1996 7.3L (3C3Z-12224-BA) OR 1997-2003 7.3L OR 2003 6.0L (3C3Z-12224-AA). THE PACKAGE CONTAINS A CONNECTOR WITH PIGTAIL, 3 BUTT SPLICES, 3 SHRINK TUBES AND INSTRUCTIONS.

 

Revised Part Number: 5C3Z-12224-A

 

 

 

16819 1999-2003 VARIOUS VEHICLES - NO CRANK, NO START

SOME 1999-2003 VEHICLES MAY EXHIBIT A NO CRANK, NO START CONDITION. THIS MAY BE DUE INADEQUATE TORQUE OF THE STARTER SOLENOID TERMINAL NUTS. TO SERVICE, CHECK THE INTEGRITY OF THE B+ TERMINAL AND S TERMINAL TORQUE. THE B+ TERMINAL NUT SHOULD BE TORQUED TO 12 +/- 1.8 NM AND THE S TERMINAL NUT SHOULD BE TORQUED TO 5.4 +/- 0.9 NM. IF THE CONCERN IS STILL PRESENT, CONTINUE WITH APPROPRIATE PC/ED DIAGNOSTICS.

EFFECTIVE DATE: 05/06/2003

 

 

 

16697 1994-2003 F-SUPER DUTIES, 1995-2003 ECONOLINE AND 2000-2003 EXCURSION 7.3L DIT ENGINE MAY EXHIBIT LOWER POWER WHEN COLD, AND AN AIR RUSHING NOISE

NORMAL OPERATION - EXHAUST AIR RUSH NOISE AND LOWER POWER. SOME 1994-2003 F- SUPER DUTIES, 1995-2003 ECONOLINE AND 2000-2003 EXCURSION WITH 7.3L ENGINE MAY EXHIBIT LOWER POWER WHEN COLD AND AN AIR RUSHING NOISE. THE TURBO CHARGER EXHAUST IS RESTRICTED BY THE EBP TO HELP INCREASE ENGINE COOLANT TEMPERATURE QUICKER FOR CAB HEAT. THIS IS CONTROLLED BY THE PCM & THE EBP REGULATOR LOCATED IN THE TURBOCHARGER PEDESTAL. THE EBP DEVICE WILL OPEN WHEN THE ACCELERATOR PEDAL IS DEPRESSED CAUSING EXHAUST BACK PRESSURE TO INCREASE. WHEN EXHAUST BACKPRESSURE DECREASES OR THE VEHICLE IS AT A STEADY STATE THE EBP REGULATOR CAN/WILL ACTIVATE THE EBP DEVICE AGAIN EVEN DURING HIGHWAY DRIVING AS LONG AS THE EOT TEMP IS BELOW SPECIFICATIONS. PCM CONTROLLED ON THE FOLLOWING PARAMETERS: IAT BELOW 10C(50F) & EOT BELOW 70C(158F)

EFFECTIVE DATE: 03/17/2003

 

 

 

16670 - 6.0L - DRIVE CONCERNS

2003 SUPER DUTY F-SERIES & EXCURSION 6.0L - DRIVE CONCERNS - CAUSED BY POSSIBLE BAD ICP SENSOR

SOME 2003 SUPER DUTY F-SERIES/EXCURSION WITH A 6.0L DIESEL MAY EXHIBIT ROUGH, ROLLING IDLE, POOR IDLE RETURN, LOW POWER, INJECTOR FAULT CODES, OR INCREASED SMOKE. THIS MAY BE CAUSED BY THE ICP SENSOR. CAREFULLY INSPECT THE ICP SENSOR CONNECTOR/TERMINALS FOR DAMAGE. VERIFY VREF & SIGNAL RETURN CIRCUITS. IF NO ELECTRICAL ISSUES, USE SCAN TOOL TO MEASURE ICP WITH EOT ABOVE 180 F. KEY OFF, WAIT 1 MINUTE MINIMUM FOR BLEED DOWN. KEY ON, WAIT 30 SECONDS. MONITOR ICP PID (READING SHOULD BE 0.18-0.24 V). IF NOT IN RANGE, CHECK NEW SENSOR (3C3Z-9F838-DA) BEFORE REMOVING OLD SENSOR. ON COOL ENGINE,CONNECT NEW SENSOR TO ICP HARNESS CONNECTOR & ENSURE NO CONTACT WITH ANY METAL COMPONENTS. KEY ON, MEASURE ICP PID (READING SHOULD BE 0.16-0.21 V). IF NOT IN RANGE, CHECK ANOTHER ICP. IF IN RANGE, INSTALL NEW ICP. CK ICP AGAIN ABOVE 180 F PER ABOVE.

 

 

 

16480 1994-2002 F-SERIES SUPER DUTY, EXCURSION, AND ECONOLINE - DTC P0340, POSSIBLE FALSE CODE

SOME 1994-2002 F-SERIES SUPER DUTY, EXCURSION, ECONOLINE, ALL EQUIPPED WITH 7.3 DIT DIESEL ENGINE MAY EXHIBIT A FALSE P0340 (DTC). A VALID P0340 SETS WHEN A CMP FAULT CAUSES A NO-START CONDITION. IF A P0340 IS PRESENT WITHOUT A NO-START CONDITION BEING ENCOUNTERED AND NO OTHER CMP DTCS (P0341, P0344) SET, DO NOT REPLACE THE CMP SENSOR. CLEAR THE P0340 DTC AND VERIFY PROPER ENGINE OPERATION. IF THE P0340 IS PRESENT IN COMBINATION WITH OTHER CMP SENSOR CODES, DIAGNOSE THE CMP CIRCUIT AS INSTRUCTED IN THE PCED.

EFFECTIVE DATE: 12/18/2002

 

 

 

16258 - 7.3L DIT UVH FALLS OUT 1998-2003 VEHICLES EQUIPPED WITH A 7.3L ENGINE (AFTER SERIAL #0661894) - UNDER VALVE COVER (UVC) HARNESS RETAINER CLIP RELEASED FOR SERVICE

SOME 1998-2003 ECONOLINE, SUPER DUTY, F650/7550 & EXCURSION WITH 7.3L (ENG SER #0661894) MAY RUN ROUGH OR MISS DURING HARD ACCELERATION DUE TO A POOR CONNECTION AT THE JUNCTION OF THE INJECTOR/GLOW PLUG HARNESS & THE VALVE COVER GASKET. IF ANY CYLINDER IS IDENTIFIED BY A CYLINDER CONTRIBUTION TEST OR IS SUSPECTED DUE TO INJECTOR PERFORMANCE ANALYZER, REMOVE VALVE COVER GASKET & INSPECT THE CONNECTION BETWEEN THE UVC HARNESS & THE VALVE COVER GASKET. THE LOCKING DEVICE FOR THE UVC MAY BECOME RELAXED & ALLOW THE CONNECTION TO FAIL. A RETAINER 2C3Z-14A163-AB IS AVAILABLE TO INSTALL IN THE LOCKING MECHANISM, SECURING THE CONNECTION. IF THE CONNECTION IS NOT SECURE, INSTALL THE CLIP & RE-EVALUATE THE ENGINE'S PERFORMANCE. DO NOT REPLACE THE INJECTOR(S) IF THE CLIP REPAIRS THE CONDITION.

 

 

 

16244 2000-2002 F-SERIES - BI-FUEL CNG/LPG NEW HEATED OXYGEN SENSOR (HEGO) DIAGNOSTIC CODES

SOME 2000 TO 2002 F-SERIES BI-FUEL CNG AND LPG TRUCKS MAY EXHIBIT UNDEFINED SERVICE CODES MAY APPEAR IN THE ALTERNATE FUEL CONTROL MODULE (AFCM) (COMPUVALVE) DUE TO UPGRADED DIAGNOSTICS. IF A CODE P2195, P2196, P2197, OR P2198 OCCURS IN THE AFCM, REFER TO DIAGNOSTIC PROCEDURES AS OUTLINED IN THE 2003 F-SERIES PC/ED. CODE DEFINITIONS: P2195 - HO2S SIGNAL STUCK LEAN (BANK 1, SENSOR 1) P2196 - HO2S SIGNAL STUCK RICH (BANK 1, SENSOR 1) P2197 - HO2S SIGNAL STUCK LEAN (BANK 2, SENSOR 1) P2198 - HO2S SIGNAL STUCK RICH (BANK 2, SENSOR 1)

EFFECTIVE DATE: 09/19/2002

 

 

16063 1994-2003 CARS & TRUCKS, CAMSHAFT POSITION (CMP) SENSOR ALIGNMENT TOOL CHART

SOME SERVICE MANUALS MAY LIST THE INCORRECT CAMSHAFT POSITION SENSOR (CMP) ALIGNMENT TOOL. REFER TO THE FOLLOWING: *T89P-12200-A (303-358)APPLIES TO: 1995 3.8L WINDSTAR,1994-1995 3.8L T-BIRD/COUGAR & MUSTANG. *T93P-12200-A (303-453) APPLIES TO: 1995 3.0L-2V TAURUS/SABLE. *T95T-12200-A (303-529) APPLIES TO: 1995- 1997 3.0L-2V WINDSTAR, AEROSTAR, RANGER), 1996-1997 3.0L-2V TAURUS, SABLE & 1996 -1998 4.0L AEROSTAR, RANGER, EXPLORER. *T96T-12200-A (303-562) APPLIES TO:1996- 1997 3.8L T-BIRD/COUGAR,1996-1998 3.8L MUSTANG,WINDSTAR,1997-2003 4.2L ECONOLINE , F-SERIES & 1996-1998 5.0L EXPLORER, MOUNTAINEER. *303-589 APPLIES TO: 1998- 2003 3.0L-2V TAURUS/SABLE, RANGER & 1998-2000 3.0L-2V WINDSTAR. *303-630 APPLIES TO: 1999-2003 3.8L WINDSTAR,MUSTANG & 1999-20005.0L EXPLORER,MOUNTAINEER. *303-638 APPLIES TO:1999-2000 4.0L EXPLORER,RANGER.

EFFECTIVE DATE: 07/26/2002

 

 

 

15661 CALIPER PIN RATTLE

SOME 1999-2002 SUPER DUTY F-SERIES (250-350) AND 2000-2002 EXCURSIONS MAY EXHIBIT A RATTLE NOISE ORIGINATING FROM THE FRONT BRAKE CALIPERS. THIS MAY BE CAUSED BY THE CALIPER PINS. IF NORMAL DIAGNOSTICS LEAD TO THE CALIPER PINS, REPLACE THE EXISTING PINS WITH THE NEW BUSHED CALIPER PINS - 2C3Z-2C150-AA (1 KIT REQUIRED PER SIDE). NOTE: SILVER PIN W/BUSHING AND BOOT IS FOR THE LOWER SIDE OF THE CALIPER. GREEN PIN W/NO BUSHING AND BOOT IS FOR THE UPPER SIDE (BLEEDER SIDE) OF THE CALIPER. EFFECTIVE DATE: 02/25/2002

 

 

 

15578 - ABS MODULE CONFIGURATION, USE NGS TO CONFIGURE

SOME 1999-2002 F-SERIES SUPER DUTY AND EXCURSION VEHICLES MAY EXHIBIT AN ABS LIGHT ON, B2141/B2477, AND/OR AN INACCURATE SPEEDOMETER. THIS MAY BE DUE TO AN INACCURATELY OR NON-PROGRAMMED ABS MODULE. TO SERVICE, USE NGS ONLY TO PROGRAM ABS MODULE USING THE FOLLOWING PROCEDURE. SELECT SERVICE BAY FUNCTIONS, ABS, TIRE SIZE/AXLE RATIO CONFIGURE, SELECT VEHICLE, ENTER CORRECT REVS/MILE AND AXLE SIZE. TO DETERMINE CORRECT REVS/MILE FOR A TIRE, DIVIDE THE ACTUAL CIRCUMFERENCE OF THE TIRE IN INCHES INTO 63360. FOR EXAMPLE, A 91" TIRE CIRCUMFERENCE WOULD EQUAL 696. YOU THEN ADD TWO ZEROES IN FRONT OF IT FOR NGS TO EQUAL 00696. FOR AXLE SIZE, SCROLL THROUGH OPTIONS AND SELECT THE APPROPRIATE ENTRY. ENGINEERING IS CURRENTLY WORKING ON A CALIBRATION FOR USE WITH THE WDS.

 

 

 

15518 NO START, NO DTC'S STORED, CHECK CKP SENSOR POLARITY

SOME 1990-2002 VEHICLES EQUIPPED WITH A CRANKSHAFT POSITION SENSOR (CKP) MAY EXHIBIT A CRANK/NO START AFTER A CKP WIRING/CONNECTOR REPAIR. IF A CRANK/NO START CONDITION OCCURS AFTER REPAIRING THE TERMINALS ON A CKP SENSOR CONNECTOR, VERIFY TERMINAL POLARITY. PCM OR EDIS SOFTWARE INCORPORATE A STRATEGY THAT DOES NOT ALLOW THE MODULE TO PROCESS A REVERSED SIGNAL WAVEFORM.

EFFECTIVE DATE: 01/07/2002

 

 

 

17508 2003-2004 SUPER DUTY F-SERIES/EXCURSION/E-SERIES 6.0L - FALSE DTC'S SET DURING USE OF ACTIVE COMMANDS WITH WDS

SOME 2003-2004 SUPER DUTY F-SERIES, EXCURSIONS AND E-SERIES VEHICLES EQUIPPED WITH A 6.0L DIESEL ENGINE MAY GENERATE FALSE DIAGNOSTIC TROUBLE CODES (DTC'S) DURING THE USE OF ACTIVE COMMANDS WITH THE WDS. COMMAND OF EGR%, VGT% AND IPR CAN GENERATE THE FOLLOWING DTC'S: P0404, P0488, P0299 (EGR%); P2263, P0478 (VGT%); P2284, P2288, P2289 (IPR). DO NOT USE DTC'S SET DURING THE USE OF ACTIVE COMMANDS TO DIAGNOSE THE VEHICLE CONCERN. IT IS IMPORTANT THAT ALL CONTINUOUS MEMORY DTC'S BE ERASED FOLLOWING DIAGNOSTICS USING ACTIVE COMMANDS. NOT CLEARING THESE DTC'S MAY RESULT IN THE MALFUNCTION INDICATOR LAMP (MIL) TURNING ON AND/OR IMPROPER COMPONENT REPLACEMENT ON RETURN SERVICE VISITS.

 

 

 

15355 P1105, P1106 - POSSIBLE FALSE DTC'S

SOME 1994-2002 E/F-SERIES AND 2000-2002 EXCURSION EQUIPPED WITH 7.3L DI ENGINE, MAY EXHIBIT FALSE DIAGNOSTIC TROUBLE CODES (DTC'S) P1105, P1106, (UPPER AND LOWER ALTERNATOR FAULTS), EVEN WITH SINGLE ALTERNATOR SYSTEMS. THE DTC'S MAY BE SET FALSELY AS A RESULT OF JUMP STARTING THE VEHICLE. TO SERVICE, DISCONNECT THE BATTERY FOR 10-15 MINUTES, RECONNECT AND RECHECK FOR DTC'S. IF THE CODES ARE STILL PRESENT CONTINUE WITH NORMAL DIAGNOSIS.

EFFECTIVE DATE: 10/31/2001

 

 

 

 

14895 - 4X4 HUBLOCK NVH

SOME 1999/2001 F-SUPER DUTY 4X4S MAY EXHIBIT NOISE, VIBRATION AND RATCHETING FROM THE FRONT WHEEL LOCKING HUBS THAT IS INITIATED BY ROAD INDUCED BUMPS OR IMPACTS. THIS CONDITION MAY BE DUE TO A DETERIORATED SPINDLE BEARING IN THE DRIVE HUB ASSEMBLY INTERMITTENTLY BINDING ON THE AXLE SHAFT. REPLACE THE SPINDLE BEARING (C6TZ-3123-A) AND INSPECT THE AXLE SHAFT FOR WEAR. IF NECESSARY, THE OUTBOARD END OF THE AXLE SHAFT (1C3Z-3B387-AA) IS AVAILABLE SEPARATELY. DURING ASSEMBLY, USE HIGH TEMPERATURE 4X4 FRONT AXLE & WHEEL BEARING GREASE (E8TZ-19590-A, ESA M1C198-A). FOR VEHICLES IN SEVERE-USE CONDITIONS, INSPECTION AND LUBRICATION OF THE BEARING PRIOR TO CONDITION ONSET CAN MINIMIZE POTENTIAL DETERIORATION.

 

 

 

 

14753 - 7.3L TURBO BOLTS LOOSE

NEW BOLT KIT RELEASED - SOME 2000-2001 SUPER DUTY F-SERIES, EXCURSIONS AND E-SERIES EQUIPPED WITH A 7.3L DIT ENGINE MAY EXHIBIT LOOSE TURBO BOLTS ON THE TURBO HOUSING. TYPICAL SYMPTOMS RESULTING FROM LOOSE BOLTS INCLUDE, LACK OF POWER AND AN OIL LEAK. TO SERVICE, INSTALL BOLT KIT #1C3Z-9G486-AA (4 REVISED BOLTS IN KIT WITH INSTALLATION INSTRUCTIONS).

 

 

 

14652 - HIGHER STEERING EFFORTS W/SITTING STILL W/BRAKES APPLIED

SOME 1999-2001 SUPER DUTY F-SERIES AND 2000-2001 EXCURSIONS MAY EXHIBIT HIGHER THAN NORMAL STEERING EFFORTS WHEN THE VEHICLE IS AT A VERY LOW SPEED OR STOPPED WITH THE BRAKES APPLIED. THIS IS A NORMAL CONDITION AND MAY BE PRESENT WITH EITHER HYDROBOOST OR VACUUM OPERATED BRAKES; THEREFORE REPAIR ATTEMPTS SHOULD NOT BE MADE.

 

 

 

14514 - CLUNK IN STEERING SOME

1997-2001 E-SERIES MAY EXHIBIT A 'CLUNK' THAT CAN BE FELT OR HEARD THROUGH THE STEERING WHEEL. THE CONDITION IS BEST EXPERIENCED IN A SLIGHT TURN, NEAR 20 MPH, ON ROAD SURFACES WITH SLIGHT IRREGULARITIES. TO SERVICE, REPLACE BOTH THE DOUBLE CARDAN JOINT (1C2Z-3E751-AA) AND LOWER INTERMEDIATE STEERING SHAFT (1C2Z-3B676-AA). DO NOT USE PRIOR LEVEL PARTS AS CONDITION MAY RETURN. REFER TO SECTIONS 211-04 OF THE E-SERIES WORKSHOP MANUAL FOR SERVICE PROCEDURE. TSB 99-09-07 MAY BE REFERENCED FOR THE PROPER PROCEDURE FOR SEATING THE STEERING BOOT. ENSURE THAT THE JOINT/SHAFT RETAINING BOLTS ARE TORQUED TO 21 LB/FT AND ALL SHAFT/JOINT CONNECTIONS ARE FULLY SEATED. NOTE: THIS CLUNK OR FEEL DOES NOT IMPACT THE FUNCTION OF THE STEERING SYSTEM AND IS CONSIDERED A CUSTOMER IRRITATION.

 

 

 

14440 INTERMITTENT INSTRUMENT CLUSTER LAMP PROVE OUT OR PCM RESET

SOME 1995-2001 SUPER DUTY F-SERIES AND E-SERIES EQUIPPED WITH 7.3L DIT MAY EXHIBIT INSTRUMENT CLUSTER LAMPS THAT 'PROVE OUT' OR CYCLE WHILE DRIVING WITH A MOMENTARY ENGINE STUMBLE AND THE ACCELERATOR PEDAL NOT RESPONDING UNTIL IT IS RELEASED. THIS MAY BE DUE TO A PCM RESET. A PCM RESET CAN BE CAUSED BY A MOMENTARY SHORT OR OPEN IN 5V REFERENCE OR 12V SUPPLY TO PCM OR IDM AND USUALLY DOES NOT HAVE DIAGNOSTIC TROUBLE CODES STORED. CHECK TSB 97-15A (7.3L DI TURBO DIAGNOSTIC REFERENCE GUIDE) PAGE 115 FOR MORE INFORMATION ON THIS CONDITION. INFORMATION ON 7.3L PCM RESET WILL BE ADDED TO FUTURE VERSIONS OF THE PC/ED.

EFFECTIVE DATE: 10/30/2000

 

 

 

14184 IMPROVED ENGINE DIAGNOSTICS - DIESEL ENGINE FUEL CONDITIONERST - SERVICE TIPS:

SOME 1999-2000 SUPER DUTY F-SERIES, ECONOLINE AND 2000 EXCURSIONS EQUIPPED WITH 7.3L DIT ENGINE MAY EXHIBIT ONE OR MORE DRIVEABILITY SYMPTOMS, INCLUDING; RUNS ROUGH, MISSES, BUCK/JERK, HESITATE/STUMBLE, SURGE, LACKS POWER, VARIOUS IDLE SYMPTOMS, MIL ON ETC... TO SERVICE, REPROGRAM THE PCM WITH THE LATEST SERVICE RELEASE CALIBRATION. THE LATEST CALIBRATIONS CONTAIN IMPROVED MAP HOSE AND WASTEGATE DIAGNOSTICS. A REVISED CALIBRATION FOR CYLINDER CONTRIBUTION TEST AND EXHAUST BACK PRESSURE (EBP) TO REDUCE THE LIKELIHOOD OF EBP VALVE SURGING IS ALSO CONTAINED IN THE LATEST CALIBRATION. NOTE: DO NOT REPLACE #8 INJECTOR TO UPDATE THE "CACKLE" REPAIR (TSB 00-10-01) FOR ANY SYMPTOM OTHER THAN ENGINE NOISE. REPLACEMENT OF THE #8 INJECTOR IS NOT AUTHORIZED FOR NON-NOISE DRIVABILITY SYMPTOMS REPAIRS.FTER AT LEAST ONE BOTTLE.

EFFECTIVE DATE: 06/06/2000

 

 

 

13990 PINPOINT TEST FOR C1113/C1115/C1185 REAR ANTI-LOCK

SOME 2000 EXCURSION, SUPER DUTY F-SERIES 250-550 AND F-53 MOTORHOME EQUIPPED WITH 'REAR ANTI-LOCK BRAKES' MAY EXHIBIT ANY OF THE FOLLOWING DIAGNOSTIC TROUBLE CODES; C1113/C1115/C1185. REFER TO THE 2000 EXCURSION/SUPER DUTY F-SERIES WORKSHOP MANUAL '4 WHEEL ANTI-LOCK' SECTION 206-09B FOR PINPOINT TEST 'K'. THE PINPOINT TEST WAS NOT INCLUDED IN THE 'REAR ANTI-LOCK SECTION' OF THE 2000 SERVICE MANUAL.

EFFECTIVE DATE: 03/20/2000

 

 

 

13965 XC3Z-9229-AA - O-RING KIT USES PINK 1-PIECE CENTER SEAL

FUEL INJECTORS FOR 1994 1/2 AND NEWER F-SERIES, ECONOLINE, EXCURSION, & F650/750 7.3L DIT EQUIPPED VEHICLES ARE NOW SERVICED WITH FUEL INJECTOR O-RING KIT XC3Z-9229-AA. AN IMPROVED SINGLE MIDDLE SEAL THAT IS PINK IN COLOR REPLACES THE SINGLE BLUE O-RING OR THE EARLY STYLE GREEN OR BLACK SEAL WITH CUSHION RING. THE NEW PINK SEAL MEASURES APPROXIMATELY 4.91 MM THICK. ONE KIT IS REQUIRED PER INJECTOR AND THIS KIT IS TO BE USED WHEN SERVICING ALL PREVIOUS DIT ENGINES.

EFFECTIVE DATE: 03/10/2000

 

 

 

13590 P0500 ADDITIONAL DIAGNOSIS INFORMATION

SOME 1999-2000 SUPER DUTY F-SERIES WITHOUT POWER WINDOWS OR LOCKS, BUILT FROM 1/1/1998 THROUGH 11/1/1999 MAY EXHIBIT ONE OR ALL OF THE FOLLOWING CONCERNS INTERMITTENTLY: MIL ON, ERRATIC AUTOMATIC TRANSMISSION SHIFTING, & DTC P0500 STORED IN MEMORY. IF THE SPEEDOMETER DOES NOT EXHIBIT ANY PROBLEMS, AND THE VEHICLE IS NOT EQUIPPED WITH THE POWER EQUIPMENT GROUP (POWER WINDOWS AND LOCKS), THEN THERE MAY BE A FAULTY CTM/GEM MODULE FEEDING BACK VOLTAGE ONTO THE VSS LINE UNDER CERTAIN CONDITIONS. TO DIAGNOSE, HAVE AN ASSISTANT MONITOR THE PCM VSS PID WHILE DRIVING. IF THE VSS PID IS ZERO ALL THE TIME, OR GOES TO ZERO WHILE DRIVING THE CTM/GEM MODULE MAY BE AT FAULT. FOR THIS FAILURE MODE, THE SPEEDOMETER WILL STILL READ ACCURATELY WHEN THE PCM VSS PID GOES TO ZERO. ONLY CTM/GEM MODULES WITH SUFFIX A-LEVEL OR F-LEVEL ARE AFFECTED. IF THE VEHICLE HAS POWER EQUIPMENT OR THE VSS PID DOES NOT GO TO ZERO, FOLLOW THE STANDARD PINPOINT TESTS OR OTHER RELATED SERVICE MESSAGES.

EFFECTIVE DATE: 12/03/1999

 

 

 

13548- IDLE KICKER ACTIVE AFTER 130 SECONDS

THE 1999.5 (DECEMBER 1998 AND AFTER) 2000-2001 SUPER DUTY F-SERIES TRUCKS AND 2000-2001 EXCURSIONS EQUIPPED WITH THE 7.3L DIT HAVE A STRATEGY THAT INCLUDES A COLD WEATHER IDLE KICKER FEATURE WHICH, UNDER CERTAIN CONDITIONS WILL AUTOMATICALLY ELEVATE THE IDLE SPEED AFTER 130 SECONDS OF IDLING AT COLD TEMPERATURES. THIS FEATURE RAISES THE IDLE SPEED UP TO A MAXIMUM OF 1200 RPM, BASED ON AIR CLEANER INLET TEMPERATURE AND THE ENGINE OIL TEMPERATURE. FOR THIS FEATURE TO BE ACTIVATED, THE TRUCK MUST BE IN PARK, (FOR THE 4R100 AUTO TRANS), OR IN NEUTRAL WITH PARKING BRAKE APPLIED (FOR M6OD MANUAL TRANS) AND ENGINE OIL TEMP BELOW 70 DEGREES CELSIUS. IDLE KICKER ACTIVE AFTER 130 SECONDS. IF ANY PEDAL OR CONTROL IS MOVED, THE ENGINE RETURNS TO BASE IDLE SPEED AND THE TIMER STARTS OVER. THIS STRATEGY RAISES THE RPM LEVEL TO THE POINT WHERE THE EBP (EXHAUST BACK PRESSURE) WORKS AND WARMS UP THE ENGINE. THE INTENT IS TO ALLEVIATE THE TENDENCY (COMMON TO ALL DIESELS) TO PRODUCE "COKING OR WET STACKING" WHEN IDLED FOR PROLONGED PERIODS AT COLD TEMPERATURES. NOTE: THESE HIGHER IDLE SPEEDS WILL HAVE A DIRECT IMPACT ON FUEL CONSUMPTION. THIS WILL ALSO CREATE A "WHOOSHING" SOUND ASSOCIATED WITH THE ACTIVATION OF THE EBP, THIS IS A NORMAL CONDITION.

 

 

 

4968 - 2003-2005 EXCURSION/2003-2006 F-SUPER DUTY - 6.0L DIESEL - HFCM HEATER DELETE

SOME 2003-2005 EXCURSIONS AND 2003-2006 F-SUPER DUTY VEHICLES EQUIPPED WITH A 6.0L DIESEL, BUILT PRIOR TO 5/16/2005, MAY REQUIRE REPLACEMENT OF THE HFCM OR MANIFOLD ASSEMBLY. THE HEATER WAS REMOVED FROM MANIFOLDS ON VEHICLES BUILT BEGINNING 5/16/2005, AND ALL MANIFOLD/SENSOR SERVICE PARTS. THERE IS A JUMPER HARNESS AVAILABLE (P/N 6C3Z-9F759-A) TO ADAPT THE EXISTING HARNESS TO THE UPDATED MANIFOLD/MODULE. A TSB WITH REVISED KIT INCLUDING ALL THE NECESSARY COMPONENTS IS BEING DEVELOPED AND WILL BE AVAILABLE BY THE END OF THE 4TH QUARTER 2005.

 

 

 

4400 - 2005-2006 F-SUPER DUTY - INSTALLATION OF UPFITTER SWITCHES ON TRUCKS NOT ORIGINALLY EQUIPPED FROM THE FACTORY

TO INSTALL THE UPFITTER SWITCHES ON A 2005-2006 F-SUPER DUTY, THAT WAS NOT ORIGINALLY EQUIPPED FROM THE FACTORY, ORDER 5C3Z-14A303-AA (WIRE ASY), 5C3Z- 13D730-AAA (SWITCH ASY), AND 5C3Z-2513546-CAA (BOX - UTILITY - LESS HOUSING). THE WIRING HARNESS BOLTS ON, AND THE SWITCH PLUGS INTO IT. THE UTILITY BOX IS ONLY NEEDED IF THE TRUCK IS NOT EQUIPPED WITH A TRAILER BRAKE CONTROLLER. IT MAY BE NECESSARY TO REMOVE THE INSTRUMENT PANEL TO INSTALL THE HARNESS FROM THE BULKHEAD SIDE. REFERENCE Q-117 WHICH CAN BE FOUND AT HTTPS://WWW.FLEET.FORD.COM/TRUCKBBAS/TOPICS/QVMP.HTML FOR ADDITIONAL INFORMATION IF NEEDED.

 

 

 

4399 - 1999-2006 F-SUPER DUTY/2000-2005 EXCURSION - LACK OF A/C COOLING - EVACUATE AND RECHARGE THE A/C SYSTEM

SOME 1999-2006 F-SUPER DUTY AND 2000-2005 EXCURSION VEHICLES MAY EXHIBIT A LACK OF A/C COOLING AT HIGHWAY SPEEDS. THIS MAY BE CAUSED BY RAPID CYCLING OF THE A/C COMPRESSOR CLUTCH DUE TO LOW SUCTION PRESSURES. TO SERVICE VEHICLES BUILT BEFORE 7/18/04, EVACUATE AND RECHARGE A/C SYSTEM WITH: - 45 OZ (1.28 KG) OF R134A ON VEHICLES WITHOUT AUXILIARY AIR. - 68 OZ (1.93 KG) OF R134A ON VEHICLES WITH AUXILIARY AIR (EXCURSION ONLY). THE LABEL ON THESE VEHICLES WILL INDICATE A DIFFERENT RECOMMENDED CHARGE LEVEL. ALL VEHICLES BUILT AFTER 7/18/2004 RECEIVED THIS REVISED CHARGE WHEN PRODUCED, BUT THE LABEL HAS NOT YET BEEN UPDATED IN PRODUCTION. FOR VEHICLES BUILT AFTER 7/18/04, AND ALL OTHER LACK OF A/C COOLING SYMPTOMS, REFER TO SECTION 412-00 OF THE WORKSHOP MANUAL FOR NORMAL DIAGNOSTICS.

 

 

3848 - 2002/03 F-Series and Excursion Belt Squeal; 99-01 with replaced belts:

Some 7.3 engines may exhibit a loud squeal noise from the engine area when the engine is under load and the fan clutch is locked up, typically in hot and dusty conditions. Another complaint may be the fan clutch oscillating or not locking up. This may be due to dust accumulating on the back side of the belt and causing it to slip on the water pump pulley. This usually affects only the 2002 model/year vehicles, but may occur in trucks built from 99-01 if the belt was replaced after July 01. On single rear wheel trucks, replace the serpentine belt with P/N 1C2Z-8620-NA on single alternator engines, and 1C2Z-8620-PA on dual-alternators.

 

0718 A service kit had been released for 2002 trucks that includes a belt, tensioner and water pump pulley. Use 2C3Z-8620-AA for single alternator and 2C3Z-8620-BA for dual alternators.

 

 

 

 

 

9998 - COPYRIGHT 2002-2006 FORD MOTOR COMPANY. ALL RIGHTS RESERVED.